Workshop Manual - PORTER 1.3 16V - Workshop

MANUALE STAZIONE DI SERVIZIO
633530 (IT) - 531 (EN) - 532 (Fr) - 533 (DE) - 534 (ES)
- 535 (PT) - 536 (NL) - 537 (EL)
PORTER 1.3 16V
MANUALE
STAZIONE DI
SERVIZIO
PORTER 1.3 16V
COPYRIGHT
Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera.
All rights reserved. Reproduction of this publication in whole or in part is strictly prohibited.
This publication has been edited by:
After sales - PIAGGIO & C. S.p.A.
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
ITALY
www.piaggio.com
MANUALE STAZIONE DI
SERVIZIO
PORTER 1.3 16V
Questo manuale per stazioni di servizio stato realizzato da Piaggio & C. Spa per essere utilizzato dalle
officine dei concessionari e sub-agenzie Piaggio-Gilera. Si presuppone che chi utilizza questa
pubblicazione per la manutenzione e la riparazione dei veicoli Piaggio, abbia una conoscenza base dei
principi della meccanica e dei procedimenti inerenti la tecnica della riparazione dei veicoli. Le variazioni
importanti nelle caratteristiche dei veicoli o nelle specifiche operazioni di riparazione verranno
comunicate attraverso aggiornamenti di questo manuale. Non si pu comunque realizzare un lavoro
completamente soddisfacente se non si dispone degli impianti e delle attrezzature necessarie, ed per
questo che vi invitiamo a consultare le pagine di questo manuale riguardanti l'attrezzatura specifica e il
catalogo degli attrezzi specifici.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. Refers to
specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to
carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing
damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
GENERAL GUIDELINES N GEN
CHARACTERISTICS CH
SPECIAL TOOLS ST
MAINTENANCE MA
EMISSION CONTROLO SYSTEM CO EM
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ES
ENGINE EN
INIECTION SYSTEM IS
GEAR-BOX GE
DIFFERENTIAL DI
BRAKING SYSTEM BS
TRANSMISSION SHAFT TS
STEERING COLUMN SC
SUSPENSIONS SS
TIPPER VERSION VR
CHASSIS CH
PRE-DELIVERY PD
TIME-SHEET TS
INDEX OF TOPICS
GENERAL GUIDELINES N GEN
RECOMMENDATIONS AND IMPORTANT NOTES
Each symbol has a specific meaning, as shown below.
WARNING:- This symbol indicates risks to the health of the operator or persons nearby, if
the procedures described are not carried out properly.
WARNING:- This symbol indicates that the component on which the operator is working
could be damaged, if the procedures described are not carried out properly.
NB: - Additional instructions related to the procedure in progress are provided in this section,
so that the operation can be performed in an efficient way.
GENERAL RECOMMENDATIONS FOR SAFETY:
1. - Always wear protective goggles and suitable clothing.
2. - Always use a safety support to work under the vehicle.
3. - Check that the ignition switch is always set to "OFF", unless otherwise specified in the procedure.
4. - Pull the hand brake before starting to work on the vehicle.
5. - Let the engine run only in well ventilated places to avoid risks related to carbon monoxide.
6. - Stand well away from moving parts during the engine operation, especially from fans and belts.
7. - In order to avoid serious burns, do not touch hot metal parts, such as the radiator, exhaust
manifold, exhaust pipe, catalytic converter and muffler.
8. - Do not smoke during maintenance operations.
9. - To avoid possible injuries, remove rings, watches, jewellery and loose clothes before starting to
work on the vehicle.
10.- Keep hands and other objects away from the electric fan blades of the radiator !
11.- The cooling electric fan is fitted on the radiator and can be started at any time due to the increase
in coolant temperature or if the air conditioner switch is set to ON, for vehicles equipped with air
conditioner. It is important to check that the cooling electric fan motor is disconnected from the
cable harness before starting work.
The units of measurement used in this manual are indicated as IS UNITS (International System
of Units). Example:24.5 34.3 Nm
The abbreviations indicated in this manual are listed in the following table.
(B) - Bolt
(S) - Screw
(N) - Nut
(W) - Washer
(T) - Tightening torque
ABBREVIATIONS
Specification Desc./Quantity
A/C: Air conditioner
API: American Petroleum Institute which assesses and classifies
the properties of the different oil types. Oils for petrol engines
General guidelines PORTER 1.3 16V
N GEN - 8
are classified as SD, SE, SF, etc. ; while those for diesel en-
gines are classified as CC, CD, etc.
A/Y Assembly A group of components or an assembled component which in-
cludes more than two single parts or subassembly parts.
ATDC: after Top Dead Centre (ATDC)
BTDC: before Top Dead Centre (BTDC)
DLC: Data Link Connector.
DLI: Distribution less ignition
DTC: Diagnostic Trouble Code indicates a code for injection system
failures.
ECU: Electronic Control Unit - Electronic unit.
EFI: Electronic Fuel Injection
ESA: Electronic Spark Advance
ETR: Electronic Tuning Radio - Radio with variable frequency, the
value varies according to voltage or current applied.
EX: Exhaust pipe / Muffler.
F/L: Fuse
GND: Bodywork ground
HC: Hydrocarbon
IGN: Injection system ignition
IN: Inlet
ISO: International Standards Organisation.
LED: Low Emission Diode
LH: Left Handed
LHD Left hand drive vehicle
MIL: Malfunction Indicator Light / Self-diagnosis warning light
MP: Multi Purpose Multipurpose, indicates that it has more than one application.
M/T: Manual / Transmission
NO: Nitric oxide
O/S: Over Size Oversize means that upon fitting, there is excessive clearance
due to extended use or due to frequent removal/ refitting oper-
ations. If the piece to be fitted (e.g. piston) is replaced with a
part with larger dimensions, the other part to be coupled can
be still used. "Oversized" parts are those which have larger di-
mensions with respect to standard parts.
PCV: Positive Crankcase Ventilation
RH: Right handed
RHD: Right hand drive vehicle
S/A: Subassembly A subassembly is a component which includes more than two
single parts which are welded or fixed with stud bolts one to the
other, constituting a single component.
SAE: Society of Automotive Engineers - Standardisation body for the
automotive industry. Lubricating oils are classified with a SAE
number. These identifying numbers are set by the Society of
Automotive Engineers of the United States of America. The
larger the SAE number, the thicker the oil is.
SST: Special Service Tool Special tool: tool designed for a specific purpose.
STD: Standard - when making reference to vehicle parts, "standard"
indicates those parts which are installed by the manufacturer
and have standard dimensions.
T: Torque This refers to the tightening torque
TDC: Top Dead Centre (TDC)
U/S: Under/ Size Undersize - as with "oversized" parts, if the mechanical part
(e.g. bushing and bearing) is replaced with a part having a
smaller diameter, the other coupled part can be reused. "Un-
dersized" parts are those parts with smaller dimensions with
respect to standard parts.
VSV: Vacuum Switching Valve Vacuum Switching Valve
W: With With
4WD: Four-Wheel Drive: vehicle with 4 driving wheels.
General information
This section comprises general information about the manual use and the vehicle, besides important
notes relevant to safety.
PORTER 1.3 16V General guidelines
N GEN - 9
Safety guidelines
Important notes about safety
Suitable maintenance and repair procedures are essential for safety, vehicle reliability purposes, as
well as for the personnel in charge of maintenance operations.
The operations described in this manual provide general information on technical procedures recom-
mended by the manufacturer necessary to guarantee product reliability. Maintenance operations
comprise various types of procedures. Technical procedures, tools and parts necessary for each op-
eration can also be significantly different from each other.
The manual does not describe all technical procedures, operations, parts, tools and instructions nec-
essary for performing maintenance operations. Therefore, anyone who consults the manual should first
and foremost have suitable technical knowledge and professional skills and assumes responsibility for
choosing the procedures to be followed, tools and parts required for proper vehicle maintenance. This
person shall bear full responsibility for actions related to their personal safety.
For this reason, operators should not carry out any operation if they are not able to make a responsible
selection of techniques and/or if they are not able to understand the content of this manual, since this
manual has been drawn up to be used by qualified personnel.
WARNING
THE PRESENCE OF A GREAT QUANTITY OF UNBURNED GASES INSIDE THE CATALYTIC
CONVERTER CAN CAUSE OVERHEATING, RESULTING IN FIRE HAZARD. TO PREVENT THIS
PROBLEM, STRICTLY OBSERVE THE FOLLOWING PRECAUTIONS, ALSO EXPLAINING THEM
TO YOUR CUSTOMERS.
PRECAUTIONS RELATED TO THE CATALYTIC CONVERTER
1. Only use unleaded petrol.
2. Do not let the engine idle for long periods. Do not let the engine idle longer than 20 minutes.
WARNING
CHECK AND REPAIR THE VEHICLE IMMEDIATELY IF IDLE SPEED IS UNSTABLE OR IF THE
SYSTEM FAILS. FAILURE TO OBSERVE THESE SPECIFICATIONS MAY CAUSE A FIRE.
3. Follow the procedure below to carry out the spark test of the spark plug. Carry out the test only if
strictly necessary and as quickly as possible. Interrupt fuel supply before carrying out this test.
4. Do not run the engine if the fuel tank is almost empty.
Failure to observe this precaution can cause an ignition failure. Besides, an excessive load on the
catalytic converter could occur, and it can even get damaged.
5. Do not dispose of the old catalytic converter together with components contaminated with petrol or
oil.
VEHICLE HAULAGE AND TOW
To haul or tow a vehicle in case of emergency, strictly follow the instructions below.
NEVER HAUL THE VEHICLE USING HARNESSES. FAILURE TO OBSERVE THIS MEASURE MAY
SERIOUSLY DAMAGE THE VEHICLE BODYWORK.
N GEN - 10
Towing on a flat truck
This is the better method to choose in order to
guarantee greater safety.
PULL THE HAND BRAKE ALL THE WAY.
TIE THE VEHICLE TO THE MEANS OF
TRANSPORT WITH SUITABLE CABLES. DO
NOT APPLY EXCESSIVE FORCE ON THE
HOOKS WHICH ARE ON THE VEHICLE BODY-
WORK OR YOU RISK DAMAGING THE BODY-
WORK.
Towing with wheels lifted.
Use a towing carriage to tow the vehicle, leaving
either front or rear wheels on the ground.
CHECK THAT THERE ARE NO PERSONS IN THE VEHICLE
BEING TOWED.
MAKE SURE TO FASTEN THE FRONT AND
REAR WHEELS TO THE TOWING CARRIAGE.
NEVER TOW THE VEHICLE USING HAR-
NESSES. FAILURE TO OBSERVE THIS PRE-
CAUTION MAY CAUSE SERIOUS DAMAGE
TO THE VEHICLE BODYWORK.
Emergency tow
This procedure can be used if the vehicle has manual transmission or if the road surfaces are firm and
even. In this case, strictly observe the safety measures indicated below
THE DRIVER OF THE VEHICLE TO BE TOWED SHALL ALWAYS TAKE INTO ACCOUNT
THAT BRAKING REQUIRES GREATER FORCE THAN NORMAL, SINCE THE POWER
BRAKE REMAINS INACTIVE ONCE THE ENGINE IS SHUT OFF.
NEVER HAUL THE VEHICLE AT A SPEED OVER 30 KM/H. SET THE IGNITION SWITCH
OF THE VEHICLE TO BE HAULED TO ACC DURING HAULAGE OPERATIONS. NEV-
ER REMOVE THE KEY OR SET THE IGNITION SWITCH TO LOCK DURING HAULAGE
OPERATIONS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE LOSS OF
CONTROL OVER THE VEHICLE AND CAUSE ACCIDENTS.
NEVER HAUL THE VEHICLE IN THIS WAY UNLESS THE WHEELS, AXLE, STEERING,
AND BRAKES ARE IN GOOD CONDITION.
WARNING
NEVER HAUL A VEHICLE WITH AUTOMATIC TRANSMISSION IN THIS WAY. ALWAYS
USE A TOWING CARRIAGE.
WHILE PULLING THE HOOK, ALWAYS KEEP IT IN AN UPRIGHT POSITION TO AVOID
DAMAGING IT. NEVER PULL IT SIDEWARDS OR VERTICALLY. ALSO AVOID SUDDEN
MOVEMENTS.
CONNECT THE TOWING ROPE, CABLE OR SIMILAR ITEMS ONLY TO THE HOOKS ON
THE VEHICLE BODY. IF THE TOWING ROPE, CABLE OR SIMILAR ITEMS ARE CON-
NECTED TO PARTS OTHER THAN THE HOOKS PROVIDED, THIS COULD SERIOUSLY
DAMAGE THESE COMPONENTS.
CHECK THAT THE HOOKS ARE FIRMLY FIXED TO THE VEHICLE BODY BEFORE
STARTING HAULAGE OPERATIONS.
1. Fix the "Towing eye" to the towing rod, avoid using ropes.
2.The driver must be inside the hauled vehicle.
3. Release the hand brake and take the gearshift lever to neutral.
4. For models with four wheel drive (4WD) move the central differential locking switch to the free position.
N.B.
N GEN - 11
IF THE ENGINE DOES NOT START, CHECK THAT THE CENTRAL DIFFERENTIAL
LOCKING DEVICE IS FREE, LIFTING ONE OF THE WHEELS AND CHECKING THAT
THESE TURN FREELY. ALSO IF THE DIFFERENTIAL LOCKING CHECKING DEVICE
WARNING LIGHT INDICATES THAT IT IS FREE, IT IS POSSIBLE THAT IT IS NOT COM-
PLETELY FREE.
5. Move the ignition switch to ACC.
6. Start haulage operations.
Lifting points
Support point for 4 arm lift
Front part:
Support the vehicle at the bodywork points indica-
ted in the figure.
(A): Front support Point
Rear part
Support the vehicle under the leaf spring.
(P): Rear support Point
N GEN - 12
Support points for jack
Front part
Place the jack on the cross-member of the front
suspension.
Rear part
Place the jack under the differential.
Maintenance guidelines
5. LOCKING TORQUE
For operations which require locking torque check, the relevant value is indicated in bold type. Make
sure to check the relevant locking torque.
3. SPECIAL TOOLS
The code of special tools necessary for individual operations is indicated in bold type.
4. MAINTENANCE PROCEDURE
The maintenance specifications are indicated in bold type or underlined. Make sure to check the relevant
specifications.
DESCRIPTION OF MANUAL USE
1. COMPONENT SKETCH
The component sketch shown at the beginning of each section describes the nomenclature
and the fitting conditions of each individual component.
Those parts marked with ( * ) can not be reused. Be careful to replace these parts with new
components during the assembly.
During the assembly, lubricate the parts marked in the figure.
(Example)
N GEN - 13
1. Brake main cylinder unit 2. Reservoir cap 3. Reservoir cap spacer 4. Reservoir diaphragm 5. Float
switch 6. Main cylinder reservoir subassembly 7. Clamp 8. Fixing bolt 9. Gasket 10. Gasket 11. Main
cylinder repair kit *: Non-reusable parts
2. MAINTENANCE PROCEDURE
- As a rule, the maintenance procedure is described in the following sequence:
removal
inspection
fitting and removal
inspection
assembly
- The explanation indicates the detailed maintenance procedure, specifications and notes.
- The main point of each item describes the section about maintenance and relevant procedure, with
the aid of illustrations.
N GEN - 14
(Example); Brake pipe fitting,
Temporarily fit the brake pipe on the
wheel cylinder, manually
Tighten the brake pipe on the wheel
cylinder, using the special tool A.
Specific tooling
09751-36011-000 tool description
- The inspection comprises only the checking operations. Therefore, if malfunctions are detected, it is
necessary to replace the defective parts with new ones.
Circuit check
Electric fault repair
DIAGNOSIS CONNECTOR (DLC Data Link
Connector).
The Electronic Control Unit of the vehicle complies
with the ISO protocol 14230 (Euro-OBD). Regard-
ing the position, the configuration of the connector
and the terminal pre-installation, the DLC complies
with the ISO 15031-3 (SAEJ 1962) and ISO 14230
standards.
The OBD II serial data line (K line) is used for the
OBD II general scanning device or for the specific
diagnostic tester, to communicate with the elec-
tronic control unit.
N GEN - 15
OBD DIAGNOSIS CONNECTOR TERMINALS:
A =OBD (DLC) Diagnosis connector
1. (+B) Battery positive (Voltage always detec-
ted: 9 14V)
2. ECU-T
3. EFI-T
4. (REV) Engine rpm signal
5. (-) Chassis ground (Resistance <10 , al-
ways detected ).
6. (- ECU) Electronic control unit ground
7. (K line) OBD serial data line (generation of
pulses on the line during transmission.
GENERAL INSTRUCTIONS FOR MAINTE-
NANCE OPERATIONS ON THE CABLE HAR-
NESS
1. Do not pull or press connectors during the trans-
port or fitting of the electrical cable harness. To
prevent possible malfunctions.
2. Do not scratch or cut the cable harness during
transport or fitting.
3. Cable harness fixing system: if there are resin
clamps, make sure that the flaps of the fixing clip
are properly inserted into the chassis hole.
- Make sure that the fixing clip does not come out
of its hole by pulling it gradually in the arrow direc-
tion.
- If there are metal clamps welded to the chassis,
make sure to fit the cable harness so that it does
not make contact with the welded metal surface or
with sharp edges to prevent possible malfunctions.
(A) Correct
(B) Incorrect
N GEN - 16
- In the case of guides or references which indicate
the fastening clamp position, make sure that it is
placed inside the guides. As regards fixing with
references, make sure that the clamp is fastened
with a maximum error of 10 mm.
C =Guide for clamp
D =The fastening clamp shall be inserted between two points.
- Terminals and connectors
E =Reference for fixing position F =Fixing shall be carried out with a tolerance of 10 mm with respect
to the reference.
4. Terminals and connectors
Connector connection:
- Connector with safety lock, make sure that the lock is properly inserted.
- Connector without lock, insert the connector until it stops at the end of the stroke.
Fixing with screws
- When the locking torque is specified, strictly fol-
low the specifications.
- Make sure that the protruding section is not on
the fixing surface.
- After fixing, pull the terminal gradually to make
sure that it is not loose.
- While carrying out other operations, make sure
not to accidentally disconnect connectors.
A =Correct B =Incorrect (terminal bent)
N GEN - 17
Using resin clamps
When using resin clamps, do not use pliers or sim-
ilar tools, as improper use could damage or cut
them.
CABLE HARNESS
- THE DIMENSION AND CAPACITY OF EACH CABLE ARE SPECIFIC TO GUARANTEE THE
PROPER OPERATION OF THE ELECTRICAL SYSTEM.
- THEREFORE, DO NOT POWER OTHER POSSIBLE ACCESSORIES USING THE EXISTING CA-
BLE HARNESS. FAILURE TO OBSERVE THIS PRECAUTION MAY CAUSE A SYSTEM MALFUNC-
TION AND ALSO FIRE HAZARD.
Disconnection of connectors with safety lock
- Press the locking lever, as shown in the figure,
then pull the connector. Do not pull the cable har-
ness, otherwise the terminals could come out of
their seats.
The locking connector can be the following types
of connector: a push-piece opening, traction open-
ing, spring closing, one-way closing mechanism
and so on.
Once the type of locking has been identified, open
the lock. Disconnect the connector holding it.
- NEVER PULL THE CABLE HARNESS WHILE DISCON-
NECTING.
- MAKE SURE TO TAKE OUT THE CONNECTOR IN AN UP-
RIGHT POSITION SO AS NOT TO DAMAGE THE TERMI-
NAL.
2. Connection.
Connect the male connector to the female connector. Make sure that the lock is completely disengaged.
3. Terminal removal.
Terminal with bayonet lock
Insert a small screwdriver (B) inside the connector
opening between the terminal and the locking lev-
er. Lever on the locking lever (A) and take out the
terminal.
N GEN - 18
Disconnection of terminal with metal lock
- Press the indicated lever in the figure with a small
screwdriver, then pull the terminal to remove it
from the connector.
4. Terminal insertion.
Terminal with box locking:
Insert the terminal in the protruding section of the connector, until the lock is completely engaged. Pull
the cable harness gradually to make sure that the lock is properly fitted.
Terminal with metal lock:
Insert the terminal in the connector, until the lock is properly engaged. Pull the cable harness gradually
to make sure that the lock is properly fitted.
DO NOT DISCONNECT A CONNECTOR WITH SAFETY LOCK, IF NOT STRICTLY NECESSARY.
BATTERY MAINTENANCE INSTRUCTIONS.
Before any intervention on the electrical system, disconnect the battery negative (-) terminal.
N.B.
BEFORE REMOVING THE GROUND LEAD FROM THE BATTERY NEGATIVE (-) POLE,
REMEMBER TO READ THE DIAGNOSTIC FAILURE CODE, IF NECESSARY.
AFTER RECONNECTING THE GROUND LEAD TO THE BATTERY NEGATIVE (-) POLE,
RESTORE ANY ACCESSORIES ON THE VEHICLE (CLOCK, RADIO, etc...)
In case it is necessary to interrupt the battery power supply to carry out repairs or maintenance; first
disconnect the negative (-) ground lead from the battery and then the positive (+) lead.
To avoid damaging the battery, loosen the nut and remove the terminal pushing it up, without turning
it or forcing it with a lever.
N.B.
USE A SPECIFIC EXTRACTOR (AVAILABLE ON THE MARKET), TO REMOVE THE
NEGATIVE (-) AND POSITIVE (+) LEADS FROM THE BATTERY POLES, SHOULD
THERE BE ANY DIFFICULTIES IN REMOVAL.
Clean the battery poles and lead terminals with a cloth.
N GEN - 19
Before connecting the ground lead to the battery, fit the terminal on the battery pole, then tighten the
terminal nut. Do not use a hammer or other tools to fit the terminal in the battery pole.
Refit the positive (+) terminal cover.
N GEN - 20
INDEX OF TOPICS
CHARACTERISTICS CH
Identification
Chassis Identification
(1) Manufacturer's label.
(2) Chassis identification number
Manufacturer label:
A - Type-approval number B - Vehicle Identifica-
tion Number C - Technically permissible maximum
total weight D - Vehicle plus trailer maximum
weight (*) E - Maximum weight permissible on front
axle F - Maximum weight permissible on rear axle
G - Vehicle model H - Type of engine
(*) NB: This option is not available in some models.
Engine Identification:
(3) Engine identification number
(4) Type of engine
Engine number and type
- The engine number is stamped on the cylinder block.
- the engine type is indicated by the letters stamped on the cylinder block
Characteristics PORTER 1.3 16V
CH - 22
VEHICLE CODE BODYWORK
S85LP-TRME Standard loading deck (Pick ) Long
loading deck (Big deck),
S85LP-TRME Tilting loading deck (Tipper)
S85LV-ZBRME Van (Blind Van)
S85LV-ZNDME 4-seat glass van (Glass van)
S85LV-TRMCE Chassis
VEHICLE MODEL CODE
The code of the vehicle model is assigned according to the following specifications:
E: EFI specifications (Electronic Fuel Injection) HC-ES E/G
M: 5-gear manual mechanical transmission
R : Standard D : De luxe
ZB : VAN ZN : GLASS VAN T : TIPPER PICK UP
V : VAN P : PICK-UP
L: LEFT GUIDE R : RIGHT GUIDE
S85: HIJ ET model
CODICE ABBIGLIAMENTO VAN
LV Pelle cloruro di vinile
LV YR: Semi tessuto
S2 Grigio
CODICE ABBIGLIAMENTO PICK-UP
LU Pelle di cloruro di vinile
LU YZ: Semi tessuto
S2 Grigio
VAN MODEL BODYWORK COLOUR CODE
W10 White
B24 Blue
R16 RED
G15 Metallic green
S13 Metallic dark grey
A01 Dark blue
PICK-UP MODEL BODYWORK COLOUR CODES
W10 White
B24 Blue
R16 RED
A01 Dark blue
Characteristics
KINEMATIC CHAIN SPECIFICATIONS
PORTER 1.3 16V Characteristics
CH - 23
CLUTCH
Engine - transmission mechanism Engine - clutch - transmission
Type Dry single disc
TRANSMISSION
Forward gear Continue drive gear
Reverse gear With sliding gears
First gear Ratio 3.769
Second gear Ratio 2.045
Third gear Ratio 1.376
Fourth gear Ratio 1.000 (-)
Fifth gear Ratio 0.838
Reverse gear Ratio 4.128
Reducer ratio 1.23 (27/22)
DIFFERENTIAL UNIT
Bevel gear pair Crown / Pinion
Gear ratio 4.444 (40/9)
WHEEL ADJUSTMENT
Toe-in 2.0 +1.5 / -1.0 mm
Camber 123' +40' / - 50' (Deck)
100' +40' / - 50' (Van)
Caster angle 313' 1 (Deck)
302' 1 (Van)
Kingpin inclination angle 1049' 1 (Deck)
1125' 1 (Van)
Rear axle Semi-floating
STEERING
Wheel outside diameter (mm) 370
Steering wheel turns 4.1
Steering Housing gear Pinion and rack
Internal steering angle () 36.0
External steering angle () 34.8
BRAKE
Front brake disc brake
Rear brake drum brake
Main brake cylinder (mm) Inside diameter 19.05
Front wheel brake cylinder (mm) Inside diameter 51.10
Rear brake cylinder (mm) Inside diameter 17.46
Parking brake Mechanical functioning acting on the rear wheels.
SUSPENSION
Front suspension Independent, McPherson type, with suspension arms and
struts fitted on silent-block.
Rear suspension Rigid semifloating axle.
Front shock absorber spring Helicoidal type
Rear shock absorber spring semi-elliptical leaf spring
Shock absorber Telescopic double-acting
CH - 24
PASSENGER PROTECTION DEVICE
Front safety belt 3 points, with ELR
GLASS
Front windshield glass Laminated
Front windshield glass 5.3 mm thickness
MOTORE
Tipo HC - ES E/G a benzina, raffreddamento ad acqua 4 cicli
N. cilindri e posizione 4 cilindri allineati, montati longitudinalmente
Meccanismo della distribuzione trasmissione a cinghia, SOHC
Alesaggio x corsa (cm) 76,0x71,4
Cilindrata (cm3) 1295
Potenza massima (kW/giri) 48,0/4800
Coppia massima (Nm/giri) 99/2800
Messa in fase dell'accensione () BTDC 3 2
Sistema di accensione ESA (Anticipo Accensione Elettronica)
Ordine d'accensione 1-3-4-2
Candela NGK BKUR6EK
DENSO K20PTR-S
Velocit al minimo (giri/min) 900 50
Registrazione delle valvole () Aspirazione Aperta: 1 prima del P.M.S.
Chiusa: 39 dopo il P.M.I.
Registrazione delle valvole () Scarico Aperta: 42 prima del P.M.I.
Chiusa: 2 dopo il P.M.S.
Gioco valvola di aspirazione (a caldo) 0,25 0,05
Gioco valvola di scarico (a caldo) 0,33 0,05
Sistema di lubrificazione lubrificazione forzata
Pompa dell'olio tipo a trocoide
Capacit olio motore Complessiva: 4,2 l
Capacit olio motore Al cambio dell'olio: 3,5 l
Capacit olio motore Al cambio dell'olio e del filtro dell'olio: 3,7 l
Raffreddamento ad acqua, del tipo a elettromotore
Tipo di radiatore Alette e Tubi
Coolant circuit 5,7 (l) heater circuit and expansion tank included.
Pompa dell'acqua centrifuga, azionata da cinghia trapezoidale
Termostato a cera (84C)
Pompa del combustibile Elettromotore
Filtro del combustibile Carta da filtro
CAPACIT
Serbatoio del carburante Capacit (Pick Up): 35 l
Serbatoio del carburante Capacit (Van): 33 l
IMPIANTO ELETTRICO
1 Alternatore trifase a corrente alternata del tipo a commutazione
2 Potenza sviluppata (V-A) alternatore 12-50
3 Regolatore di tensione IC Regolatore
4 Potenza (V-kw) motorino avviamento 12-0,8
Van
CH - 25
Pick-Up
CH - 26
Tightening torques
ENGINE
Name Torque in Nm
Cylinder head - Water outlet joint 1522
Cylinder head - Water temperature sensor 24.5 34.3
Water pipe - Radiator electric fan thermal switch 2030
Cylinder block - Water pump 15 22
Cylinder block - Water inlet joint 6 9
Catalytic converter - Muffler 39 54
Exhaust pipe - Catalytic converter 42 56
Exhaust manifold - Front exhaust pipe 4262
0X1 Oxygen sensor - Exhaust manifold 29.4 39.2
0X2 Oxygen sensor - Exhaust manifold 29.4 39.2
Oxygen sensor - Exhaust manifold 2939
Cylinder head - Exhaust manifold 35 53
Cylinder head - Inlet manifold 15 22
Inlet manifold - Fuel delivery pipe 611
Inlet manifold - EGR pipe 1522
Inlet manifold - EGR valve 1522
EGR valve - EGR pipe 4771
Inlet manifold - Throttle body 1522
Fuel tank - Canister bleed valve bracket 3.9 6.9
Camshaft sensor - Cylinder head 1522
Oil sump - Cylinder block 712
Oil filter - Cylinder block 1522
Oil pump - Cylinder block 69
Cover - Oil pump 813
Oil pressure switch - Cylinder block 1220
Oil pump body - Oil pump cover 813
Oil pump - Oil pressure switch 1220
Intake pipe for oil in sump - Oil sump 15 - 22
Cylinder block - Oil pump 69
Clutch cover 1522
Connecting rod - Connecting rod cap 3444
Engine shaft - Camshaft control belt pulley 1522
Crankshaft - Crankshaft belt pulley 8898
Crankshaft - Flywheel 7898
Cylinder block - Rear bottom plate 1015
Cylinder block - Generator bracket 3449
Cylinder block - Transmission 4969
Cylinder block - Rear oil seal ring 69
Cylinder block - Main bearing cap 44 54
Cylinder head - Cylinder block 5967
Cylinder head - M 8 Camshaft 1317
Cylinder head - M 10 Camshaft 2936
Cylinder head - Cylinder head cover 9 13
Cylinder head - Spark plug 15 22
Valve adjustment lock nut 17 22
Timing system pulley screws 1522
Crankshaft - timing system pulley screw 88 98
Timing system belt tensioner 2944
Crankshaft pulley - transmission screws 2029
Timing belt cover screw 24
Cylinder head cover - Ignition coil 611
Generator fixing screws - M8 1822
Generator fixing screws - M10 2832
Fuel filter fixing nut 34 43
Cover - Thermostat 5.9 8.8
Radiator - Water thermal switch 24.5 5
Generator shaft fixing nut: 110
Generator - Pulley 80
CH - 27
BODYWORK
Name Torque in Nm
Muffler front pipe - Exhaust joint 39.2 53.9
Instrument panel support - Chassis 18 28
Rear seat safety belt - Chassis (external) 28.4 53.0
Rear seat safety belt - Chassis (internal) 28.4 53.0
Front seat safety belt - Chassis (inside) 28.4 53.0
Radiator protection bar - Chassis 28.4 53.0
Front seat - Seat slide tracks 14.7 23.5
Adjustable seat back regulator - Front seat 22.6 44.1
Engine compartment cap - Chassis 9.8 15.7
Front seat back - Front seat 18.6 30.4
Tail door support - Tail door 17.7 23.5
Door stop plate - Chassis 20 - 30
BRAKE SYSTEM
Name Torque in Nm
LSPV brake calibrator - Rear axle 10 16
LSPV brake calibrator - Bracket 15 22
Parking brake cable - Chassis 4.0 6.8
Disc brake dust guard - Wheel hub articulation 39.3 53.9
Front hub or drum - Front axle shaft or front axle 176.6 215.7
Disc brake calliper - Disc brake dust guard 49 59
Brake disc dust guard - Wheel hub joint 39.3 53.9
Power brake - Pedal assembly plate 17.7 21.5
Brake calibrator - Brake pipe 13 18
Brake pipe - Wheel brake cylinder 12.8 17.6
Wheel cylinder - Bleed cap 6.9 9.8
Supporting plate - Wheel cylinder 9.9 12.7
Main cylinder - Pedal bracket 29.5 44.1
Brake pipe joint - Brake cylinder 10 12
STEERING AND SUSPENSIONS
Name Torque in Nm
Tie rod head - Articulated arm 39 54
Tie rod head - Tie rod head lock nut 34.3 53.9
Central arm - Tie rod head 39.3 53.9
Central arm - Front suspension cross-member 111.7 137.3
Longitudinal rod end - Longitudinal rod 68.6 88.2
Rack guide protection lock nut - Steering rack housing 34 44
Steering rack - Steering rack No. 1 49.0 68.6
Steering rack housing - Body 53.9 68.6
Flexible coupling - Steering pinion flange 9.8 15.7
Flexible coupling - Intermediate shaft 9.8 15.7
Universal joint 19.6 29.4
Flywheel - Steering shaft 29.4 39.2
Nut - Leaf spring shackle 29.4 49.0
U-bolt - Leaf spring buffer 44 54
Spring support pin - Leaf spring assembly. 88 108
Rear axle shaft housing - Rear shock absorber (lower part) 34.3 53.9
Rear shock absorber - Chassis (upper part) 34 54
Shoe holding plate - Rear axle shaft housing 63.7 70.4
Shock absorber - Front suspension support 49.0 69
Steering joint - Front shock absorber 78.5 98
Brake dust guard - Steering joint 39.2 53.9
Tie rod head - Steering joint 39.2 53.9
Suspension lower arm - Steering joint 73.5 93
Strut bracket body 39 54
Cross-member - Suspension lower arm 78.5 98.0
Strut bracket - Suspension lower arm 69 88
Castle nut - Front axle hub 177.0 216.0
Wheel rim nuts - Wheel hub 88 118
Rack spring cap 7
CH - 28
PROPELLER SHAFT AND DIFFERENTIAL
Name Torque in Nm
Differential flange - Propeller shaft 3954
Differential bearing support - Differential support 6074
Pinion - Differential coupling flange 162 199*
Rear axle - Oil filler cap 3963
Universal joint - Rear differential flange 3954
Filler cap - Differential cover 39.2 - 49.00
Differential cover - Differential housing 8.5 2
Differential housing - Crown gear 66.5 - 73.5
* Value to be determined according to pinion bearing preloading.
GEAR RETAINERS
Name Torque in Nm
Propeller shaft - Rear differential flange 3954
Clutch lower cover - Gearbox 47
Direct connection bolt - Transmission 4969
Engine rear bracket - Gearbox 2944
Rear bearing lock - Gearbox 1522
Gear control fork shaft screw - Clutch housing 1930
Reverse lever - Gearbox 1522
Inlet shaft bearing locking plate - Clutch housing 15 22
Gearbox - Oil filler cap 29 49
Gearbox - Cover 29 44
Clutch housing - Gearbox 15 22
Rpm indicator locking plate - Gearbox cover 7 10
Reverse limiting shaft screw - Gearbox 19 22
Gearbox cover - Gearbox 15 22
Reverse limiting pin lock - Gearbox 29 49
Lock nut - Main shaft 177216
Reverse transmission gear shaft screw - Gearbox 19 31
Rear engine support bracket - Chassis 49 69
CLUTCH RETAINERS
Name Torque in Nm
Brake pedal - Brake pedal support 1522
Clutch cover - Flywheel 1522
Vehicle overhaul data
Cylinder-piston oversizes
CYLINDER CLOCK
Cylinder - standard diameter (mm) 76.000 76.030
Cylinder diameter - 1st oversize (mm) 76.250 76.280
Finishing angle of the liner 35 5
Roughness 1 - 4Z
PISTON
Standard diameter piston (mm) 75.965 75.995
1st oversize diameter piston (mm) 76.215-76.245
Cylinder - Piston standard clearance (mm) 0.025 0.045
Maximum clearance between Cylinder - Piston (mm) 0.11
Clearance between piston and pin (mm) 0.005 - 0.011
CH - 29
Piston ring oversizes
OPENING CLEARANCE AFTER USE - PISTON RINGS
Piston ring max. clearance 1 (mm) 0.7
Piston ring max. clearance 2 (mm) 0.8
Max. clearance between piston ring 3 and oil scraper (mm) 1.0
STANDARD OPENING - PISTON RINGS
Piston ring 1 (mm) 0.27 0.37 with reference letter T
Piston ring 1 (mm) 0.27 - 0.40 with reference letter N
Piston ring 2 (mm) 0.45 - 0.55
Oil scraper ring 3 (mm) 0.20 - 0.60 (mm) - type A
Oil scraper ring 3 (mm) 0.15 - 0.60 (mm) - type B
THICKNESS - PISTON RINGS
Compression piston ring 1 (mm) 1.17 1.19
Compression piston ring 2 (mm) 1.47 1.49
Piston ring max. clearance C (mm) 0.12
Piston - Pin
PIN
Pin outside diameter (mm) 18.994-18.997
Pin coupling interference - Rod small end (mm) 0.015 0.044
Crankshaft - Rod head
CRANKSHAFT
Connecting rod pin bearing diameter (mm) 49.976 - 45.000
Main journal bearing diameter (mm) 49.976 - 50.000
Connecting rod pin standard coupling clearance (mm) 0.020 - 0.044
Main journal standard coupling clearance (mm) 0.024 - 0.042
Connecting rod pin maximum coupling clearance (mm) 0.050
Main journal maximum coupling clearance (mm) 0.050
Standard axial clearance (mm) 0.02 - 0.20
Maximum axial clearance (mm) 0.30
Maximum eccentricity clearance (mm) 0.06
CONNECTING ROD
Rod small end standard diameters (mm) 18.953-18.979
Connecting rod head standard diameters (mm) 48 000 - 48.024
Connecting rod head axial clearance (mm) standard 0.15-0.40
Connecting rod head axial clearance (mm) Maximum limit. 0.45
Maximum off-line (mm) 0.05
Maximum torsion (mm) 0.05
CH - 30
Valve guide - Valve stem
VALVES
Valve stem diameter (mm): Intake valve: 6.6 -0.020-0.040
Valve stem diameter (mm): Outlet valve: 6.6 -0.025-0.045
Valve length: (mm) Intake valve: 112.8
Valve length: (mm) Outlet valve: 114.5
Valve base thickness: (mm) Intake valve: 0.8
Valve base thickness: (mm) Outlet valve: 1.0
Stem - guide coupling clearance (mm) Intake valve: Standard 0.020 - 0.055
Stem - guide coupling clearance (mm) Maximum limit: 0.080
Stem - guide coupling clearance (mm) Outlet valve: Standard 0.025 - 0.060
Stem - guide coupling clearance (mm) Maximum limit: 0.090
Valve seat angle () 45.5
Tappets
VALVE CLEARANCE
Intake valve clearance (mm) 0.25 0.05 [hot engine]
Outlet valve clearance (mm) 0.33 0.05 [hot engine]
Distribution timing Intake - Open - 1 before TDC
Distribution timing Intake - Closed - 39 after BDC
Distribution timing Outlet - Open - 42 before TDC
Distribution timing Outlet - Closed - 2 after BDC
ROCKING LEVERS AND PINS
Rocking lever hole diameter (mm) 19.500-19.521
Rocking lever pin outside diameter (mm) 19.468 19.488
Rocking lever standard clearance (mm) 0.015 0.053
Maximum limit (mm): 0.08
Unloaded width (mm) 22.00
Valve spring
VALVE SPRINGS
Valve spring unloaded length (marked in ORANGE) 47.4 mm
Valve spring unloaded length (marked in PINK) 45.2 0.5 mm
Valve spring minimum unloaded length (marked in ORANGE) 46.1 mm
Valve spring minimum unloaded length (marked in PINK) 43.9 mm
Valve spring preloading (marked in ORANGE) 208.9 N to 38.0 mm (Standard fitting height)
Valve spring preloading (marked in PINK) 244.9 N to 38.0 mm (Standard fitting height)
Obliquity maximum limit (mm) 1.6
Camshaft
CAMSHAFT
Camshaft maximum eccentricity 0.03 mm
Camshaft bearing coupling clearance (mm) 0.035 0.076
Camshaft bearing maximum coupling clearance (mm) 0.17
Camshaft axial clearance (mm) 0.1 0.25
Camshaft maximum axial clearance (mm) 0.45
CH - 31
Intake cam standard height (mm) 33.435 33.634
Intake cam minimum height (mm) 33.2
Outlet cam standard height (mm) 33.17 33.37
Outlet cam minimum height (mm) 33.0
Testata motore - montaggio e serraggio
INLET - EXHAUST MANIFOLD
Unevenness (mm) 0.1
CYLINDER HEAD
Cylinder block side unevenness (mm): 0.10
Inlet manifold side unevenness (mm): 0.10
Exhaust manifold side unevenness (mm): 0.10
Inlet valve seat angle (mm) 30 45 70
Exhaust valve seat angle (mm) 20 45 70
TIMING SYSTEM SHAFT PULLEY
Timing system shaft pulley diameter (mm) 119.94
Timing shaft pulley wear limit 119.8
CRANKSHAFT PULLEY
Crankshaft pulley diameter (mm) 59.37
Crankshaft pulley wear limit (mm) 59.3
CH - 32
INDEX OF TOPICS
SPECIAL TOOLS ST
Tooling
INJECTION SYSTEM TOOL
Stores code Description
020680Y Srumento diagnosi - Navigator
020682Y Cablaggio interfaccia EOBD - Navigator
020460Y Diagnostic tester
020463Y ECU-EFI interface cable harness to
check the injection system electrical val-
ues.
020618Y Cable harness for connecting the OBD
Connector and the Diagnostic Tester
020469Y Reprogramming kit for Diagnostic tester
Special tools PORTER 1.3 16V
ST - 34
020492Y CD Software Porter 1300 16V
020331Y Digital multimeter
020274Y Checking tool kit
020400Y Fuel pressure checking kit
020275Y Cable harness to check fuel injection
ENGINE TOOL
020180y Engine support
020387Y Tool to remove or replace the valve guide
bushing
PORTER 1.3 16V Special tools
ST - 35
020401Y Clutch guide tool (clutch fitting)
020398Y Punch (sealing ring fitting)
020388Y Box-spanner for spark plugs (Spark plug
removal and refit)
020382Y Tool to remove the valve cotters
TRANSMISSION TOOL
020206y Bearing extractor
CLUTCH TOOL
020195y Tool kit to align the diaphragm spring
020196y Clutch guiding tool
020197y Instrument to measure the height of the
clutch diaphragm spring
ST - 36
DIFFERENTIAL TOOL
020293y Expanding tool
020286y Adaptor for attachment to the engine sup-
port
020284y Tool to adjust pinion position
020177y Pinion bearing replacement kit
020213Y Bearing extractor
020212y Flange locking tool
ST - 37
020211y Flange oil seal extractor
BRAKE TOOL
020221y Brake drum stop device
020222y Front hub and drum extractor
FRONT SUSPENSION TOOL
020224y Connecting rod bushing extractor and
changer
020235y Front spiral spring compressor
020231Y Tie rod head extractor
ST - 38
020188y Axial hub support and driving pinion tool
series - Front axle bearing and differential
pinion replacement kit
020223y Extractor and changer for front suspen-
sion arm bushing
REAR SUSPENSION TOOL
020227y Rear wheel bearing extractor
020226y Rear axle shaft extractor
020225y Buffer to fit the rear bridge bearing
ST - 39
020201y Gear bearing fitting punch
0.20222y Front hub and drum extractor
0.20200y Oil seal extractor
STEERING TOOL
0.20228y Rear conical tool to replace the differen-
tial control pinion bearing
0.20229y Roller bearing extractor and tool to re-
place the oil seal
ST - 40
0.20230y Tool to replace the differential control pin-
ion bearing
ST - 41
INDEX OF TOPICS
MAINTENANCE MA
Scheduled maintenance chart
SCHEDULED MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY; C : CLEAN; R : REPLACE; A : ADJUST;
L : LUBRICATE
* Check level every 5,000 km ** Replace every 2 years
km x 1,000 10 20 30 40 50 60 70 80 90 100 110 120
Safety clamps I I I I I I I I I I I I
Engine oil * R R R R R R R R R R R R
Gearbox Oil R R R
Differential Oil R R R
Oil filter R R R R R R R R R R R R
Air filter C C C R C C C R C C C R
Fuel filter R R
Coolant level ** I I I I I I I I I I I I
Brake fluid level ** I I I I I I I I I I I I
Generator belt I I I I R I
Timing belt R
Idle speed - Engine
timing
I I I I I I
Ignition spark plug I I I I I I
Valve clearance I I I
Accelerator control I I I I I I
Clutch control I I I I I I
Fuel hoses I I I
Oil vapour recovery
pipe (blow by)
I I I
Suspensions I I I
Steering wheel I I I I I I
Brake pedal and park-
ing brake lever
I I I I I I
Parking brake cable I I I I I I
Brake flexible hoses I I I I I I
Brake drum - Brake
gasket
I I I
Brake disc - Brake
pads
I I I
Radiator - Cooling sys-
tem hoses
I I I I
Transmission (lubrica-
tion)
L L L L L L
Electrical system and
battery
I I I I I I I I I I I I
Headlight aiming A A A A A A
Tyre pressure and
wear
I I I I I I I I I I I I
Test drive I I I I I I I I I I I I
OPERATION TIMES 115' 240' 115' 265' 115' 240' 115' 265' 115' 240' 115' 265'
EVERY 2 YEARS
Brake fluid Replacement
Coolant Replacement
EVERY 4 YEARS
Servo brake Operation
PORTER 1.3 16V Maintenance
MA - 43
Suggested products chart
PRODOTTI CONSIGLIATI
Product Description Specifications
AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, API
GL-5
Gearbox oil
AGIP BRAKE FLUID DOT4 Brake fluid FMVSS DOT 4
AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2
AGIP ARNICA 46 Oil for hydraulic tilting system pump Oil for hydraulic systems in compliance
with ISO VG 46, DIN 51524 HVLP
AGIP SUPERDIESEL MULTIGRADE
15W-40
Engine oil SAE 15W-40, API CF-4/SG
AGIP SINT EVOLUTION Olio motore (indicato per climi freddi) SAE 5W-40, API SL, ACEA A3
Engine assembly
N.B.
ADJ USTMENTS OR SERVICES DESCRIBED IN THIS SECTION ARE CARRIED OUT AS
A GENERAL RULE WHEN THE ENGINE IS HOT.
A "HOT ENGINE" MEANS THAT CONDITION IN WHICH THE COOLING FAN HAS BEEN
ACTIVATED AT LEAST ONCE.
CHECK THAT ALL THE ACCESSORY SWITCHES ARE SET TO OFF.
THE GEARSHIFT LEVER SHALL BE IN NEUTRAL.
PULL THE HANDBRAKE ALL THE WAY.
POSITION THE STEERING WHEEL SO THAT THE WHEELS ARE PERFECTLY
ALIGNED.
CHECK THAT THOSE PARTS REMOVED FOR ADJ USTMENTS OR CHECKS ARE RE-
FITTED.
Air filter
1. Remove the filtering element from the air filter
housing.
2. Visually inspect the filtering element and check
that it is not too dirty, damaged or oily. If necessa-
ry, replace the filtering element.
3.Blow compressed air over the entire lower sec-
tion A of the filtering element. Then, do the same
with the upper section B.
4.Refit the filtering element into the filter housing.
Close the housing.
Maintenance PORTER 1.3 16V
MA - 44
Engine oil replacement
Engine oil level check
Check that the engine oil level is between the
L and F marks on the dipstick to check oil
level.
If the oil level is below the reference mark L, top
up with recommended oil until the reference mark
F is reached. Make sure that there are no leaks.
USE SPECIFIC OIL OR OIL WITH A HIGHER
COEFFICIENT OF VISCOSITY.
THE QUANTITY OF OIL BETWEEN THE "L"
AND "F" REFERENCE MARKS IS EQUIVA-
LENT TO APPROX. ONE LITRE.
Characteristic
Engine oil capacity at MAX level
3.5 l ("F" level)
Engine oil capacity at MIN level
2.5 l ("L" level)
Engine oil capacity (engine sump + filter)
3.7 l
Total engine oil capacity
4.2 l
Oil quality check
Check that the engine oil is not deteriorated, dis-
coloured or diluted, and that there is no water
infiltration.
N.B.
PARK THE VEHICLE ON A LEVEL SURFACE.
MA - 45
Engine oil change and filter replacement
1. Shut off the engine after warming it up for a few
minutes; remove the protection cover;
2. Remove the oil drainage plug and empty the
engine sump;
3. Remove the oil filter with a suitable wrench;
4. Check and clean the filter fitting surface.
5. Apply engine oil on the sealing ring of the new
filter before fitting it.
6. Finger screw the oil filter until the sealing ring
makes contact with the filter fitting surface.
7. Tighten the oil filter 3/4 of a turn with a filter
wrench
8. Clean the oil drainage plug. Fit the plug and
place a new gasket in between.
- REMOVE GASKET WASTE OFF THE OIL SUMP USING A
SUITABLE SCRAPER.
9. Pour oil in the engine until the maximum level in
the oil dipstick is reached.
10. Start the engine and check that there are no
leaks.
11. Stop the engine.
12. Check the level again and top up, if necessary.
Leaks
Check that there are no oil leaks from the gasket.
Gear-box oil replacement
Sostituzione olio cambio
Gearbox oil change
1. Remove the drainage plug and the filler cap.
Drain the gearbox oil.
2. Refit the drainage plug and place a new gasket in between.
3. Top up with recommended oil until it starts to come out through the fill opening.
Recommended products
AGIP ROTRA MP 80W-90 Transmission oil
MA - 46
SAE 80W-90, API GL-5
4. Refit the filler cap and place a new gasket in between.
Locking torques (N*m)
Gearbox cover for filler cap 30 49
Oil leaks
Check the gearbox for oil leaks.
Check the gearbox oil level.
1. Remove the filler cap.
2. The gearbox oil level must reach the level in-
spection hole or should be below 5 mm.
Differential oil replacement
Differential oil change
1. Remove the drainage plug and the filler cap. Drain the differential oil.
2. Refit the drainage plug and place a new gasket in between.
3. Top up with recommended oil until it starts to come out through the fill opening.
AGIP ROTRA MP 80W-90 Differential oil
4. Refit the filler cap and place a new gasket in between.
Differential oil cap 39 59 Nm
Oil leak
Check that the differential does not leak oil.
MA - 47
Coolant replacement
Check
Check that the coolant level is between the MINI-
MUM and the MAXIMUM reference notches in the
auxiliary reservoir. If the coolant level almost rea-
ches the minimum or is below the MINIMUM level,
add coolant until the MAXIMUM level is reached.
NEVER REMOVE THE RADIATOR CAP WHILE
THE ENGINE STILL HOT. FAILURE TO OB-
SERVE THIS SAFETY MEASURE MAY CAUSE
BURNS.
N.B.
IF THERE IS NO COOLANT IN THE AUXILIARY
RESERVOIR OR IF THE FLUID LEVEL IS TOO
LOW, CHECK THERE ARE NO WATER LEAKS
USING THE APPROPRIATE TESTER.
THE COOLANT SHOULD HAVE A SUITABLE
ANTIFREEZE DEGREE.
N.B.
USE A TOP QUALITY ETHYLENE GLYCOL
BASED ANTIFREEZE SOLUTION.
N.B.
THE QUANTITY INDICATED ABOVE IN-
CLUDES THE LITRES FOR THE EXPANSION
TANK.
Characteristic
Coolant reservoir capacity:
5.7 litres
Coolant change
NEVER OPEN THE RADIATOR CAP AND/OR THE DRAINAGE PLUG WHEN THE ENGINE IS STILL
HOT.
A. Take the heater control lever to "hot".
B. Remove the radiator cap 3.
C. To drain the coolant, remove the drainage plugs
located on the radiator lower reservoir and the ra-
diator pipe.
D. Remove plug 2 on the engine side and plug 1
of the heater bleed pipe on the upper part of the
engine.
E. Insert a pipe in the radiator fill opening. Clean
the radiator internal side. During this operation
keep the engine at idle speed.
F. Shut off the engine. Refit and close the drainage
plugs.
MA - 48
G. Pour coolant in the radiator. When the coolant
starts coming out through hole 2 located on the
engine side and through the heater bleed pipe,
close both openings.
H. Pour coolant until the fluid comes out through
the radiator fill opening.
I. Close the radiator cap 3 completely.
L. Clean the expansion tank internal side. Fill up
with coolant.
M. Start the engine and warm it up to the operating
temperature.
N. Make sure there are no leaks.
O. After the fluid temperature decreases, remove
plug 2 located on the engine side. Check the cool-
ant level. If the level is too low, add coolant. Tight-
en plug 2 again.
DURING THIS PHASE, NEVER OPEN THE RADIATOR CAP
3 SO THAT COOLANT DOES NOT COME OUT THROUGH
CAP 2.
KEY:
1. Radiator cap
2. Radiator cap
3. Radiator cap
4. Radiator
5. Engine
P. Check the coolant level in the expansion tank.
Add water until the maximum level is reached. Re-
fit the expansion tank cap.
MA - 49
Leaks
A. Fill up the radiator with coolant. Connect the
tester to the radiator cap.
B. Warm up the engine.
C. Apply a 117 kPa pressure to the cooling system
by means of the tester connected to the radiator
cap.
D. Make sure there are no leaks.
Spark plug
Cable check
1. Disconnect the ignition coil connector. After-
wards, remove the ignition coil by taking out the
fixing nuts.
2. Disconnect the spark plug from the cable.
3. Carefully remove the spark plug cable from the
ignition coil.
4. Visually inspect the spark plug cable by check-
ing if there are signs of wear, cracks or any other
damage.
Spark plug check
1. Remove the spark plugs.
2. Spark plug visual inspection.
Visually inspect the spark plug by checking wheth-
er the electrodes are worn and that the thread or
the insulator is damaged. If necessary, replace the
spark plug.
3. Electrode gap inspection.
Measure the electrode gap with the appropriate
thickness gauge.
MA - 50
If the gap between the electrodes of a used spark
plug does not match the specified values, replace
the spark plug with a new one.
If the gap between the electrodes of a new spark
plug does not match the specified values, adjust
the distance by bending the earth electrode base;
pay attention not to touch the central electrode.
CANDELE CONSIGLIATE
DENSO K20PTR-S Distanza elettrodi mm: 0,9 1,0
NGK BKUR6EK 0,9 1,0
Settings and Adjustments
Headlight alignment check
Light beam direction adjustment
Before adjusting direction, carry out the following
operations:
- Make a person sit down at the driving position.
- Check tyre pressure and adjust if necessary.
- Make sure that the following components are
properly fitted: spare wheel, jack, toolkit bag.
- Check level, and if necessary, top-up: engine oil;
gearbox oil; windshield fluid, etc.
- Move the vehicle in different directions so its
weight is proportionally distributed so that the ve-
hicle can take a correct position.
- Cause the engine to run at 1500 rpm or more
during headlamp adjustment.
- Set the headlamp switch to "0".
MA - 51
1. Set a screen three meters away from the head-
lamps.
2. Measure the headlamp height from the ground
"H".
3. Turn the set screw for headlamp aiming 1 until
the limiting line between the dark and bright areas
is 36 mm shorter than "H". Distance "A" between
the headlamp axes must be 1020 mm.
MA - 52
INDEX OF TOPICS
EMISSION CONTROLO SYSTEM CO EM
Emission check: this section of the manual describes operations and precautions to be followed to check
emissions.
EMISSION CONTROL SYSTEM
Crankcase gas recirculation: A system by means of which the gas generated in the crankcase re-
enters the inlet manifold, instead of being released to the atmosphere, in order to be burned inside the
combustion chamber.
Three-way catalytic converter: A device by means of which hydrocarbons (HC) and carbon monoxide
(CO) contained in exhaust fumes are oxidised, and Nitric oxides (NOx) are deoxidised by the monolithic
catalytic converter, thus minimising HC, CO and NOx emissions that are released into the atmosphere.
Closed-loop control system (EFI) (Electronic Fuel Injection): The closed-loop control system guar-
antees a suitable air-fuel ratio for the engine. It also guarantees optimum quantity of oxygen contained
in the exhaust fumes so as to obtain a high degree of purification of the three-way catalytic converter.
Electronic ignition timing control ESA (Electronic Spark Advance): Thanks to the electronic igni-
tion timing control based on signals sent by the various sensors, the computer controlling emissions
keeps the ignition timing constant at optimum levels, according to engine conditions.
Fuel closing in deceleration (Cut-off): Device that interrupts fuel supply during the deceleration phase
in order to reduce HC and CO emissions. System by means of which Nitric oxide (NOx) emissions are
minimised, thus allowing recirculation of exhaust fumes present in optimum quantity in the inlet manifold
according to engine conditions.
Fuel vapour emission check: System by means of which hydrocarbons (HC) released by the fuel tank
are absorbed by an activated carbon filter (CANISTER), thus preventing the emission of hydrocarbons
(HC) into the atmosphere.
HC: Hydrocarbons
CO: Carbon monoxide
NOx: Nitric oxides
Disposizione componenti
COMPONENT LAYOUT
1. Activated carbon filter
2. Vacuum switching valve for bleeding
3. Oil filler cap
4. Atmospheric opening
5. Activated carbon filter
6. VSV (vacuum switching valve) for EGR (exhaust gases recirculation)
7. EGR vacuum modulator
8. EGR (exhaust gases recirculation) valve
9. Throttle body
10. Bleed opening
Emission Controlo System PORTER 1.3 16V
CO EM - 54
11. EGR (valve ) opening
12. To the fuel tank
13. To the fuel tank
14. Atmospheric opening
A =Crankcase gas recirculation system
B =Fuel vapour control system
Catalizzatore
Catalytic converter
A cylindrical three-way catalytic converter having
a monolith is assembled under the bodywork, be-
tween the exhaust manifold and the main silencer.
The three-way catalytic converter can treat all
three components CO, HC and NOx simultane-
ously in a single unit. When the exhaust emissions
are purified by the three-way catalytic converter,
the purification characteristics mainly depend on
PORTER 1.3 16V Emission Controlo System
CO EM - 55
the engine air-fuel ratio. That is to say, when the
air-fuel ratio is lean, the quantity of oxygen after
combustion increases. Oxidation becomes active
while reduction becomes inactive . Instead, when
the air-fuel ratio is rich, oxidation becomes inactive
while reduction becomes active. It is therefore nec-
essary to keep the air-fuel ratio constantly within
the limits of the stoichiometric air-fuel ratio. This
can be obtained with the Electronic Control Unit,
according to the signals by the oxygen sensors,
both front and rear.
Cr =Low - Purification ratio (%) - High
Mr =Rich - Air-fuel ratio - Lean
A =Range to be used
1. Converter
2. ID number
3. Monolithic catalytic converter
Sistema di controllo dei vapori carburante
Fuel vapour control system
With this system, hydrocarbon (HC) emissions evaporated from the fuel feed circuit are reduced. During
operation, vapours that form in the fuel tank enter the activated carbon filter. Carbon absorbs fuel va-
pours, keeping them in the filter. When the throttle valve is opened during engine operation, the manifold
vacuum acts on the activated carbon filter. In this way, the fuel vapours captured, together with clean
air, are carried into the throttle body to be burned. In the figure, the full arrows show the clean air path
whereas the dotted arrows show the fuel vapours path.
CO EM - 56
CONTROL SYSTEM DIAGRAM
A. Electronic control unit of the electronic fuel injection
B. Vacuum switching valve - evaporation
C. Air filter
D.Throttle body
E. Filter
F. Activated carbon filter
G. bleed checking valve - evaporation
H. Carburettor chamber
Engine off
High tank pressure: Hydrocarbon emissions are absorbed by the activated carbon filter (only valve 2
open)
Average tank pressure: The activated carbon filter captures hydrocarbon emissions (All valves closed)
Low tank pressure:
The activated carbon filter captures hydrocarbon emissions (All valves closed. When the pressure inside
the fuel tank dramatically drops, the valve opens so that the fuel tank does not get damaged. )
Engine operation with the accelerator pedal pushed
High tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in by
the engine (only valve 2 open)
Average tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in
by the engine (only valve 2 open)
Low tank pressure: Hydrocarbon emissions absorbed by the activated carbon filter are sucked in by
the engine (only valve 2 open)
CO EM - 57
Blow-by ventilation pipe (crankcase vapour re-
covery)
Check that there are no signs of wear or strangling
on the pipe and that it is properly connected.
Fuel closing device during deceleration
The fuel closing device stops fuel supply during deceleration in order to reduce hydrocarbon and CO
emissions, also avoiding catalytic converter overheating.
For HC-ES engines, this device is checked by the program set for the Electronic Control Unit of the
Electronic Fuel Injection.
It is checked when the throttle valve is completely closed and when the engine speed exceeds the set
value.
Besides, the initial and return engine speed to stop fuel is preset according to the temperature of the
engine cooling water.
Air-fuel mixture control system
The closed-loop control system guarantees a suitable air-fuel ratio in the engine. Besides, it guarantees
an optimum quantity of oxygen in the exhaust fumes so as to obtain a high degree of purification of the
three-way catalytic converter.
A =Injector
B =Combustion chamber
C =Front oxygen sensor
D =Three-way catalytic converter
E =Rear oxygen sensor
F =Elect. control unit of the elect. fuel injection
G =Engine coolant temperature sensor
CO EM - 58
H =Pressure sensor
I =Intake air temperature sensor
Fuel vapour control device
1. Visual inspection of fuel vapour ducts and
connections.
Check pipes and connections for any leaks, see if
they are entangled or damaged.
2. Visual inspection of the fuel tank.
Check the fuel tank for possible deformations,
cracks or petrol leaks. Replace the fuel tank, if
necessary.
- MAKE SURE THAT NEITHER THE ACTIVATED CARBON
FILTER FITTING IS REDUCED NOR THE FUEL TANK CAP
DAMAGED
3. Fuel tank cap check
Check that the fuel tank cap and the gasket are not
damaged or deformed.
4. Activated carbon filter check
A. Detach the pipe bracket from the activated car-
bon filter.
B. Detach the rubber pipes from the activated car-
bon filter.
C. Remove the activated carbon filter from the ve-
hicle by pulling the filter housing upwards.
- BEFORE DETACHING THE RUBBER PIPES, APPLY A LA-
BEL ON EACH PIPE SO AS TO REFIT THEM IN THEIR
ORIGINAL POSITION.
CO EM - 59
D. Visually check the activated carbon filter hous-
ing for breaking or damage. Replace the activated
carbon filter if it is damaged.
E. Check that no air leaks through the activated
carbon filter. Check leaks by injecting compressed
air at 29.4 kPa (0.3 kgf/cm2) into the pipe on the
fuel tank side B with the pipes on bleed side A and
atmosphere side C closed. In case of air leaks, re-
place the activated carbon filter with a new one.
F. Check that there is no reduction in the activated
carbon filter.
a) Check for air continuity in the pipe on the at-
mosphere side C by blowing air into the pipe on
the fuel tank side B with the pipe on the bleed side
A closed. If there is no air continuity, replace the
activated carbon filter with a new one.
b) Check for air continuity by applying a negative
pressure to the pipe on the bleed side A using the
MityVac device.
If there is no air continuity, replace the activated
carbon filter with a new one.
G. Activated carbon filter cleaning.
Clean the activated carbon filter by blowing com-
pressed air at 294 kPa (3.0 kg/cm2) inside the pipe
on the fuel tank side B with the pipes bleed side of
filter A closed.
H. Fit the activated carbon filter on the vehicle.
I. Reconnect the rubber pipes and refit the new
pipe bracket.
- DO NOT TRY TO WASH THE ACTIVATED CARBON FIL-
TER.
- THE ACTIVATED CARBON MUST NOT COME OUT DUR-
ING THE TEST. SHOULD THIS OCCUR, REPLACE THE
ACTIVATED CARBON FILTER.
CO EM - 60
5. Vapour bleed control valve inspection
A. Disconnect the rubber pipes from the vapour
bleed control valve.
- BEFORE DETACHING THE RUBBER PIPES, APPLY A LA-
BEL ON EACH PIPE SO AS TO REFIT THEM IN THEIR
ORIGINAL POSITION.
B. Remove the vapour bleed control valve from the
fuel tank by undoing the relevant fixing bolts.
C. Visually inspect the vapour bleed control valve
for cracks or damage.
If damage of any kind is found, replace the valve
with a new one.
D. Check that no air leaks through the vapour
bleed control valve. Make sure that there are no
air leaks by injecting compressed air at 29.4 kPa
(0.3 kgf/cm2) into the pipe on the fuel tank side,
with the pipe on the activated carbon filter side and
pipes on the atmosphere side closed.
In case of air leaks, replace the valve with a new
one.
E. Check the vapour bleed control valve for reduc-
tions.
a) Check that there is no air continuity in the pipe
on the atmosphere side by blowing air inside the
pipe on the fuel tank side, with the pipe on the ac-
tivated carbon filter side closed.
CO EM - 61
b) Check that there is air continuity in the pipe on
the activated carbon filter side by blowing air into
the pipe on the fuel tank side.
c) Check there is air continuity by applying a neg-
ative pressure to the pipe on the activated carbon
filter side using the MityVac device.
In cases in which there is no air continuity, replace
the valve with a new one.
F. Fit the valve on the upper side of the fuel tank.
I. Reconnect the rubber pipes and fit the new bracket.
Sistema di controllo delle emissioni allo scarico
Emission control device
1. Check that the fixing nuts are not loose. Tighten
the catalytic converter nuts again, if necessary.
AFTER TIGHTENING THE NUTS, CHECK
THAT NO EXHAUST FUMES LEAK THROUGH
THE CATALYTIC CONVERTER FLANGE.
IF EXHAUST FUME LEAKS ARE DETECTED,
REPLACE THE GASKET.
Check that the exhaust pipe attachment is not
loose.
Catalytic converter fixing nuts 39 54
Check that the oxygen sensor (lambda probe) is not loose.
Tighten it, if necessary.
CO EM - 62
N.B.
CHECK THAT NO EXHAUST FUMES LEAK THROUGH THE OXYGEN SENSOR (LAMBDA
PROBE) ATTACHMENT.
Exhaust manifold for oxygen sensor 29.4 39.2 Nm
4. Check the oxygen sensor (lambda probe) cable
for signs of cracks or other kinds of damage. If
necessary, replace the oxygen (lambda probe)
sensor with a new one.
5. Check that the oxygen sensor (lambda probe)
connector is properly connected and fixed. Other-
wise, connect and fix the connector properly.
Exhaust emission control system
Fuel vapour emission control device
1. Visual inspection of the connections and the
fuel vapours duct.
Check that ducts and connections are not loose,
twisted or damaged.
2. Visual inspection of the fuel tank.
Check that there are no deformations, cracks or
fuel leaks. Replace the fuel tank, if necessary.
N.B.
CHECK THAT THE ACTIVATED CARBON FILTER PIPE IS
NOT OBSTRUCTED AND THAT THE FILLER CAP HAS NO
DEFECTS.
CO check
CO/HC concentration check
Arrangements before the CO/HC concentration check.
- Pull the handbrake all the way.
- Check and adjust ignition timing
- Check and adjust idle speed.
- Warm up the engine.
- Take all the accessory switches to OFF.
- Fit the filtering element.
- Connect all the pipes and the low-pressure pipe.
- Check that there are no air leaks in the intake system.
- Check that there are no gas leaks in the exhaust system.
CO EM - 63
- Take the gearshift lever to neutral.
- Position the steering wheel so that the wheels are perfectly straight.
- Prepare the CO/HC meter according to the manufacturer's instructions.
THIS CHECK IS NECESSARY TO DETERMINE IF HC/CO EMISSIONS WITH THE ENGINE AT IDLE
COMPLY WITH THE REGULATIONS IN FORCE.
Measure HC/CO emissions by inserting one probe of the meter in the exhaust pipe. Wait for at least
one minute before measuring so that concentrations stabilise. Finish the measurement within three
minutes. If HC/CO concentrations do not comply with the regulations in force, consult the following table
to determine the probable causes.
HC CO Problem Possible cause
High Regular Irregular idle speed 1. Faulty ignition
- Inaccurate ignition timing
- Spark plugs dirty, short-circuited or with incorrect
electrode gaps
2. Incorrect valve clearance
3. Exhaust valves with leaks
4. Cylinder with leaks
High Low Irregular idle speed (Fluctua-
tions in reading HC )
1. Lean mixture causing irregular ignition
High High Irregular idle speed (Black
smoke in exhaust pipe)
1. Air filter clogged
2. Defective electronic fuel injection system
- Pressure regulator defective
- Reverse fuel pipe clogged.
- Water temperature sensor defective.
- Air temperature sensor defective.
- Gas position sensor defective.
- Pressure sensor defective.
- Electronic Control Unit defective.
- Oxygen sensor (lambda probe) defective.
CO EM - 64
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
Engine
Starting difficulties
DIFFICULT STARTING
Possible Cause Operation
Pipes clogged Check/replace damaged parts
Fuel filter clogged Replace
Air in the fuel feed circuit Bleed and check seals
Faulty fuel supply pump Replace
Flat battery Check/Replace
Unstable battery connections Check and restore contacts
Faulty key switch Replace
Faulty starter motor Replace damaged parts
Air filter clogged Replace
Injection advanced Check advance
Black smoke from exhaust
BLACK EXHAUST SMOKE
Incorrect injection pump calibration Check
Air filter clogged Replace
Injection delayed Check injection advance
White smoke from exhaust
WHITE EXHAUST SMOKE
High oil level Restore the level
Piston rings worn or seized Check/replace
Worn or scored cylinders Check and grind if possible
Worn valve guides Check/Replace
Low oil pressure
LOW OIL PRESSURE
Pressure adjustment by-pass blocked Check/Replace
Worn oil pump Check/Replace
Air to the oil intake pipe Check/Replace
Faulty pressure switch Check/Replace
Oil intake pipe clogged Check/Replace
Main bushings/connecting rod worn Check the crankshaft and when possible, recondition it
Increase of oil level
OIL LEVEL INCREASE
Fuel feed injection-pump faulty Replace
Troubleshooting PORTER 1.3 16V
TROUBL - 66
Leak from injection-pump unit Check and replace damaged components
Cylinder-head gasket damaged Replace
Excessive oil consumption
EXCESSIVE OIL CONSUMPTION
High oil level Restore the level
Low idle Adjust correctly
Piston rings worn or seized Check and replace damaged components
Worn or scored cylinders Check and replace damaged components
Worn valve guides Check and replace damaged components
Oil and fuel leakage from exhaust
OIL AND FUEL LEAK AT EXHAUST
Prolonged running at idle Accelerate several times with engine in neutral
Low idle Adjust correctly
Worn or scored cylinders Check and replace damaged components
Worn valve guides Check and replace damaged components
Coolant overheats
COOLANT OVERHEAT
Cylinder-head gasket damaged Replace and check the cooling circuit
Air in the cooling circuit Bleed
Coolant leaks from the system Check/replace damaged components
Cooling fan damaged Replace
Clutch
Clutch slipping
CLUTCH SLIPS
Discs, pressure plates and flywheel wear Check/replace damaged components
Belleville spring stretched or damaged Check/replace damaged components
Oil or grease on disc friction material Check and clean
Clutch gripping
ROUGH CLUTCH
External controls hardened Check the control unit components, adjust correctly and re-
place damaged components
Deformed clutch disc Check/replace damaged components
PORTER 1.3 16V Troubleshooting
TROUBL - 67
Oil or grease on disc friction surfaces Check and clean
Clutch does not disengage and drags
CLUTCH DOES NOT DISENGAGE AND DRAGS
Deformed clutch disc Check/replace damaged components
External controls seized Check the control unit components, adjust correctly and re-
place damaged components
Controls not properly adjusted Adjust
Noisy clutch at engagement and/or disengagement
NOISY CLUTCH WHEN ENGAGING AND/OR DISENGAGING
Clutch disc with damaged anti-vibration buffer springs Check/replace damaged components
Gearbox
Gears disengage abruptly or are difficult to engage
SPONTANEOUS DISENGAGEMENT AND DIFFICULT ENGAGEMENT
Levers and gear tie rods incorrectly adjusted Adjust
Control rod retaining springs fault Replace the springs
Synchroniser coupling teeth or coupling sleeve teeth fault Check/replace damaged components
Incomplete coupling travel Check the components of the selection and gear engaging unit,
replace damaged components
Gears difficult to engage
DIFFICULT COUPLING
Levers and gear tie rods incorrectly adjusted Adjust
Synchronisers or coupling sleeves fault Check/replace damaged components
Sliding problems in internal controls: rods, forks and sleeves Check/replace damaged components
Hardening and/or seizing of levers and tie rod gears Check the unit components, adjust correctly and replace dam-
aged components
Central clutch hardening Check/replace damaged components
Noisy gears
GEARSHIFT NOISE
Worn or faulty internal component Check/replace damaged components
Brakes
TROUBL - 68
Brakes overheat
SHOE SLIPPAGE ON THE DRUMS
Insufficient clearance between shoes and drums Self-adjusting device locked
Shoe return spring weak or damaged Replace
Pump pistons or cylinders locked Check the unit
Drums and shoes worn or scored Overhaul
Locked brakes
BRAKES BLOCKED
Shoe return springs stretched Replace
Rubber gaskets swollen or seized Check the system, replace all the rubber parts and the fluid,
bleed air from the system: use the recommended oil
Rusty plungers Replace
Incorrect position of brake pedal stop Adjust
Brake pedal elastic response
BRAKE PEDAL FLEXIBLE MOVEMENT
Air in the system Bleed the system
Hoses that swell under pressure due to wear Replace or bleed the system
Air leak in the pump due to poor tightness of rubber rings Replace the rings
Brake pedal too soft
BRAKE PEDAL SINKS TOO MUCH
Tank cap breather hole blocked causes vacuum in the pump
for air to pass through the gasket
Clean the tank cap and bleed the system
Fluid leak from fittings, cylinders and hoses Check and replace damaged components
Suspensions and steering
Noisy suspension
FRONT SUSPENSION NOISE
Wheel axle bearings worn or with excessive clearance Replace
No grease in the wheel hub chamber Remove, grease or replace the bearings
Inefficient or leaking shock absorbers Replace
Worn ball joints Replace
Worn steering box Replace
REAR SUSPENSION NOISE
Wheel axle bearings worn or with excessive clearance Replace
No grease in the wheel hub chamber Remove, grease or replace the bearings
PORTER 1.3 16V Troubleshooting
TROUBL - 69
Rear suspension spring buffers damaged Replace
Swinging arm to chassis attachment silent blocks damaged Replace
Vibration sent from engine to chassis
VIBRATIONS TRANSMITTED FROM ENGINE TO CHASSIS
Silent blocks fixing engine to chassis not properly locked or
damaged
Lock or replace
Difficult riding
DRIVING PROBLEMS
The vehicle pulls to one side Check any steering arm alterations and then check toe-in
Steering hardening or knocking Check the steering assembly components (column-housing
joints, steering, etc.)
Inefficient or leaking shock absorbers Replace
Incorrect tyre pressure Restore the correct pressure
TROUBL - 70
INDEX OF TOPICS
ELECTRICAL SYSTEM ES
Ground points
PUNTI DI MASSA
BATTERY-CHASSIS GROUND
Electrical system PORTER 1.3 16V
ES - 72
SERVICES SYSTEM GROUND (under the instru-
ment panel on the Left side)
SERVICES SYSTEM GROUND (under the instru-
ment panel on the Right side)
MAIN GROUND (Gear cover - Chassis)
REAR SERVICES SYSTEM GROUND(PICK)
PORTER 1.3 16V Electrical system
ES - 73
ADDITIONAL GROUND (between the engine and
the left longitudinal arm).
INJECTION SYSTEM - ENGINE GROUND (cor-
respond to the ground terminals in the control unit).
Electric circuit diagram
Legenda
1. Batteria
ES - 74
2. Starter
3. F/L principale 60A
4. Interruttore avviamento
5. Alternatore 50A
6. Altoparlante
7. Radio
8. Accendisigari
9. Comando tergicristallo
10. Comando tergilunotto (modello van)
11. Teleruttore tergicristallo
12. Pompa tergicristallo
13. Motore spazzole tergicristallo
14. Fusibile ACC 15A
15. Fusibile
16. Pompa tergilunotto
17. Motore spazzole tergilunotto
18. Teleruttore elettroventola
19. Fusibile motore 20A
20. Elettroventola
21. Termointerruttore
22. Interruttore fanali fendinebbia posteriori
23. Teleruttore fanali fendinebbia posteriori (2)
24. Teleruttore fanali fendinebbia posteriori (1)
25. Comando regolazione proiettori
26. Interruttore luci
27. Luce fendinebbia posteriore
28. Attuatore regolazione proiettore sinistro
29. Attuatore regolazione proiettore destro
30. Interruttore luci anabbaglianti
31. Diode
32. Luci abbagliante/anabbagliante
33. Luci fendinebbia
34. Teleruttore luci fendinebbia anteriori
35. Interruttore luci fendinebbia anteriori
36. Spia luci abbaglianti
37. Fusibile lampade 20A
38. Fusibile H/L Left 10A
39. Fusibile H/L Rigth 10A
ES - 75
40. Fusibile fendinebbia 20A
41. Interruttore luci di posizione
42. Luci di posizione
43. Illuminazione comandi riscaldamento
44. Luce di posizione anteriore
45. luce di posizione anteriore
46. Illuminazione quadro strumenti
47. Luci targa
48. Luce di cortesia posteriore (per van)
49. Luce di cortesia
50. Interruttore su portellone posteriore per luce di cortesia
51. Interruttore Luce di cortesia anteriore
52. Buzzer
53. Fusibile clacson/lampeggiatori 15A
54. Fusibile Lunotto termico 10A
55. Interruttore lunotto termico
56. Lunotto termico
57. Interruttore luci stop
58. Luci stop
59. Interruttore clacson
60. Clacson
61. Dispositivo lampeggiatori
62. Deviatore lampeggiatori
63. Indicatore quattro lampeggiatori
64. Indicatori di direzione anteriori e posteriori destri
65. Indicatori di direzione anteriori e posteriori sinistri
66. spia indicatori di direzione
67. Sensore livello carburante
68. Quadro strumenti
A. Spia diagnostica
B. Spia ricarica batteria
C. Spia Pressione olio
D. Spia freno di stazionamento
E. Spia liquido freni
F. Indicatore temperatura
G. Indicatore livello carburante
H. Spia riserva carburante
69. Interruttore liquido freni
ES - 76
70. Interruttore freno a mano inserito
71. Interruttore pressione olio
72. Luce retromarcia
73. Interruttore luce retromarcia
74. Fusibile riscaldamento
75. Fusibile starter
76. Centralina elettronica (EFI ECU)
77. Interruttore per elettroriscaldatore
78. Resistenza elettroriscaldatore
79. Motorino elettroriscaldatore
80. Centralina elettronica (controllo diagnostico)
81. Sensore temperatura aria
82. Sensore temperatura liquido raffreddamento
83. Rivelatore velocit veicolo
84. Sensore quantit aria
85. Sensore pressione
86. Resistore (EFI)
87. Sensore riscaldatore posteriore
88. Sensore riscaldatore anteriore
89. Sensore angolo di rotazione
90. Cablaggio candele
91. Spinotto 1
92. Spinotto 2
93. Spinotto 3
94. Spinotto 4
95. Bobina accensione
96. Teleruttore Principale
97. E/G J /CA
98. Fusibile EFI1 15A
99. Fusibile EFI2 15A
100. Motore F/P
101. Teleruttore F/P
102. Iniettori
103. IDOL UP VSV
104. PURGE VSV
105. EGR VSV
ES - 77
Electric diagrams
Ignition
IGNITION SYSTEM DIAGRAM
1. Battery
2. F/L fuse
3. 60A F/L main fuse
4.F/L IG 1 fuse
5. 20A Engine fuse
6. Ignition unit (Igniter)
7. Coils
8. Ignition spark plugs
9. ECU control unit
ES - 78
10. Throttle valve sensor
11. Data Link Connector (DLC)
12. Engine coolant temperature sensor
13. Vehicle speed sensor
14. Pressure sensor
15. Cam angle sensor
Ignition system
This section of the manual provides information to check the correct operation of the ignition system.
Starting and recharging
START-UP AND RECHARGE
1. Main switch (IG)
2. 60A Fuse
3. Battery
4. 20A Motor fuse
5. 20A Heating fuse
6. Battery recharge warning light
7. Voltage regulator with integrated circuit
8. Alternator
ES - 79
START-UP AND RECHARGE:
1. F/L fuse
2. Fuse (60A)
3. Ignition switch
4. Battery
5. Starter motor
6. 10A Start-up fuse
7. EFI ECU control unit
Iniezione
ES - 80
Aria Condizionata
AIR CONDITIONING ELECTRICAL SYSTEM DIAGRAM
1. Instrument panel.
2. A/C control micro-switch with recirculation lever set to ON.
3. Ventilation selector.
4. 7-way connector (female).
5. 7-way connector (male).
6. 7-way connector (female.
ES - 81
7. 7-way connector (male).
8. 20A Fuse.
9. Fuse-box.
10.Resistor.
11.Cab electric fan.
12.Terminal from ground to eyelet (-31).
13.Switch relay - Cab electric fan control (1st speed).
14.5-way connector (connects evaporator control to electric fan control).
15.Evaporator assembly.
16.Air Conditioning A/C switch.
17.Bulb.
18.De-icer thermostat.
19.2-way connector (connects engine electrical system to vehicle electrical system).
20.Terminal from ground to eyelet (-31).
21.Switch relay - Electric fan control.
22.30A Fuse
23.Switch relay - Electric fan control.
24.60A Fuse
25.Switch relay - Compressor electromagnetic coupling control.
26.7.5A Fuse.
27.Water thermostatic sensor.
28.3-way connector (connects Electrical system to Electric fan).
29.Electric fan.
30.NC Thermostatic sensor normally closed (control to release compressor electromagnetic coupling
with water temperature >117C).
31.Compressor electromagnetic coupling
32.A/C system protection pressure switch.
33.3-way connector.
34.Generator.
35.Engine.
36.Depression fitting.
37.Solenoid valve of accelerated idle control (VSV MIN ).
38.2-way connector.
39.Breather pipe.
40.Depression fitting.
41.Electric fan operation logic.
(*) NB: The sketched parts represent components of the original electrical system.
ES - 82
COLOUR TABLE
ITALIAN FRENCH ENGLISH GERMAN SPANISH GREEK
Arancio Orange Orange Orange Naranjado
Azzurro D'azur Light Blue Hellblau Azul
Bianco Blanc White Weiss Blanco
Blu Bleu Blue Blau Turqui
Giallo J aune Yellow Gelb Amarillo
Grigio Gris Grey Grau Gris
Marrone Marron Brown Braun Marrn
Nero Noir Black Schwarz Negro
Rosa Rose Pink Rosa Rosa
Rosso Rouge Red Rot Rojo
Verde Vert Green Grn Verde
Viola Violet Violet Violett Violado
Fuses
Fuse box
Fitting position: The fuse box is located on the left
side of the steering wheel, either in right- or left-
hand drive vehicles.
Instructions to replace fuses and fuse holders
1. Before replacing a fuse, find the problem that caused the fuse to blow and/or the fuse holder to burn.
2. Repair the malfunction, and fit a new fuse and/or fuse holder, use only an identical one and with the
same capacity.
3. Before removing or fitting fuses into the fuse holder, make sure that the key switch is set to OFF.
4. Use small pliers to remove or fit fuses.
FUSE BOX
(A) Main fuse box
(B) Auxiliary fuses
(C) Windscreen wiper activation position.
(D) Flashing turn indicators activation position.
ES - 83
Teleruttori
REMOTE CONTROLS:
1. Fuel pump remote control 2. Control unit
main remote control 3. Rear fog light remote
control 1 4. Rear fog light remote control 2
5. Windscreen wiper intermittence remote con-
trol 6. Turn indicator intermittence remote con-
trol
7. Front fog lights remote control (optional
equipment)
8. Radiator electric fan remote control
ES - 84
AIR CONDITIONING REMOTE CONTROLS
13 - Cab electric fan control remote control (first
speed). 20 - Ground with eyelet terminal. 21 -
Electric fan control switch remote control 22 - 30A
Fuse 25 - Compressor electromagnetic coupling
control remote control 26 - 7.5A Fuse
Electrical controls
Multifunction switch lever
Check
1. Make sure that turn indicators, low-beam/high-beam lights, hazard indicator and windscreen wiper
switches work properly.
2. Disconnect the multifunction switch lever connector. Make sure there is continuity between the rel-
evant terminals according to the continuity tables shown in the following diagram.
ES - 85
KEY:
1.Windscreen wiper switch
2. Windshield spray nozzle switch with automatic return system
3. Hazard indicator switch
4. Turn indicators switch with automatic return system
5. Light switch
6. Low-beam light switch
KEY:
1. Turn indicators switch with automatic return system
2. Light switch
3. Low-beam light switch
4. Indicator switch
5. Windscreen wiper switch
6. Windshield spray nozzle switch with automatic return system
Key-switch
Ignition key switch
1. Remove the ignition key switch cylinder unit.
ES - 86
2. Make sure that battery voltage is applied to terminal B regardless the ignition key switch position.
3. Disconnect the connector.
<DIV class=cnt_summary title="Testo Breve (<4000 car.)">4. Make sure there is continuity among the
relevant terminals as indicated in the table below.
KEY:
A =Terminal
B =Cable colour
Continuity table
C =Position
D =Terminal
ES - 87
Wiper switch
Rear windscreen wiper and spray nozzle
switch
TERMINALS:
0= Windshield washer spray WASH2
1= Windscreen wiper first position
2= Windshield washer spray WASH1
TERMINALS:
1= From the spray nozzle motor
2= To ground
3= To ground
4= From the windscreen wiper motor
Make sure there is continuity between the relevant terminals as indicated in the following table.
Continuity table
A= Switch
B= Terminal
Interruttore luci stop
Check
1. Disconnect the stop light switch.
2. Make sure there is continuity between terminals
when the brake pedal is pushed.
3. Make sure there is no continuity between termi-
nals when the brake pedal is not pushed.
ES - 88
Interruttore freno stazionamento
Handbrake switch
1. Take out the handbrake connector and perform
continuity checks between the terminal and the
body ground.
2. Make sure there is continuity between terminals
when the handbrake lever is pulled.
3. Make sure there is no continuity between termi-
nals when the handbrake lever is released.
Lunotto termico
Heated rear window switch
1. Remove the heated rear window.
2 Make sure there is continuity between the respective terminals as indicated in the table below.
KEY:
1=To the defroster
2=Ground
3=Switch
C=Bulb
Continuity table
A= Switch
B= Terminal
Interruttore regolazione proiettori
Headlamp light beam adjustment switch
1. Remove the switch for headlamp light beam adjustment.
2. Check continuity between the terminals, as indicated in the following table.
ES - 89
Continuity table
A= Switch
B= Terminal
3= Ground
Interruttore luci fendinebbia
Front fog light
1. Remove the front fog light switch.
2. Check continuity between the terminals, as in-
dicated in the following table.
1= To the front fog light
2= Ground
3= Switch
Continuity table
A= Switch
B= Terminal
ES - 90
Windscreen wiper mechanism
Check
1. Low speed operation check.
Connect terminal 3 to the battery positive (+) ter-
minal; terminal 1 to the battery negative (-) termi-
nal. Then, connect terminal 2 to terminal 5. Make
sure that the windscreen wiper operates at low
speed.
2. High speed operation check.
Connect terminal 3 to the battery positive (+) ter-
minal; terminal 1 to the battery negative (-) termi-
nal. Then, connect terminal 2 to terminal 4.
Make sure that the windscreen wiper operates at
high speed.
3. End of operation check.
After checking operation at high and low speeds,
connect terminal 2 to terminal 4, or connect termi-
nal 2 to terminal 5.
Make sure that the windscreen wiper works and
stops at the automatic stop position.
ES - 91
KEY:
1. Arm and blade
2. Connection unit
3. Motor
4. Windscreen wiper
Windscreen wiper circuit diagram
Windscreen wiper remote control
Location: Fuse block upper part
Make sure that there is continuity between:
Terminals 2 and 3: There is continuity between
Terminals 2 and 4: There is no continuity
ES - 92
1. Connect terminal 4 to the battery positive (+)
terminal.
2. Connect terminal 1 to the battery negative (-)
terminal.
3. Make sure that a noise (a click) is heard indi-
cating functioning. The relay is set to ON.
4. Connect terminal 3 to terminal 1. Then (about a
second later), connect terminal 3 to terminal 4. The
relay is set to OFF.
5. After about four seconds a noise indicating func-
tioning must be heard (intermittent operation).
Installation
1. Fit the windscreen wiper motor with the connec-
tion unit.
2. Run the motor and take it to the automatic stop
position.
3. Position the blades in their respective positions
as shown in the figure.
4. Fit the instrument panel.
Characteristic
Driver-side arm length
441 mm
Passenger-side arm length
416.5 mm
Driver-side blade length
400 mm
Passenger-side blade length
380 mm
Removal
1. Remove the windscreen wiper and the blade arm.
2. Remove the instrument panel.
3. Remove the hexagon nut.
4. Remove the windscreen wiper motor with the connection unit.
Components
ES - 93
KEY:
1. Arm and blade
2. Connection unit
3. Motor
4. Windscreen wiper
Rear wiper mechanism
KEY:
1. Nut
2.Rear window wiper blade and arm
3. Connection cover
4. Hexagon nut
5. Washer
6. Connection gasket
7. Motor unit
ES - 94
Diagram
Fitting
1. Fit the rear window wiper motor.
2. Run the motor until it reaches the automatic stop
position.
3. Align the blade with the lower line of the rear
defroster. Tighten the nut.
Removal
1. Remove the rear window wiper and the blade holder arm.
2. Remove the connection cover and the hexagon nut.
3. Remove the washer and the connection gasket.
4. Remove the engine unit.
Check
1. Connect the rear window wiper motor body to
the battery negative (-) terminal.
2. Connect terminal S to the battery negative (-)
terminal.
3. Connect terminal B to the battery positive (+)
terminal. Make sure that rear window wiper is
working.
4. In the operation conditions described above,
disconnect terminal S from the battery negative (-)
terminal. Make sure that the rear window wiper
stops at the automatic stop position.
Starter motor
Start-up system
ES - 95
This section of the manual describes the start-up system and provides information to check for its correct
operation.
Removal and fitting operations are also described.
Starter motor maintenance instructions
1. Pay attention when locking the starter motor terminal or the battery terminal properly; if the connection
is not correct, there is serious risk of overheating due to a strong passage of current upon starting the
vehicle.
2. Before removing the starter motor, disconnect the battery negative (-) terminal. Then, disconnect
terminals (+B, ST) from the motor. Since battery voltage is always applied to terminal +B of the starter
motor, carefully observe the removal sequence to avoid causing a short circuit in the battery, which is
extremely dangerous.
3. When refitting the starter motor, make sure to tighten the bolts observing the relevant locking torque.
Any incorrect refit can result in early wear of pinion teeth or flywheel crown, or even cracking of the
crankcase.
Inspection with starter motor fitted
1. Take the gearshift lever to neutral. Pull the
handbrake lever.
2. Disconnect the ignition coil connector so that the
motor does not start.
3. Turn the ignition switch to ST. Check that the
motor starts running.
4. If the motor does not turn, check if the battery is
damaged or discharged. Perform the cable har-
ness continuity test.
5. If despite the above checks, the starter motor
does not start, remove the motor and check it.
ES - 96
Componenti
KEY:
1. Starter motor assembly
2. Bushing
3. Transmission seat
4. Engagement lever
5. Retention collar
6. Circlip
7. Coupling
8. Rotor
9. Reed
10. Stator
11. Brush holder
12. Clamp C
13. Bushing
14. Cover
15. Rubber ring
16.Safety plate
ES - 97
17. Support cap
18. Remote control
Rimozione dal veicolo
Removal
1. Disconnect the starter motor cables.
2. Remove the starter motor from the clutch cover.
Bench tests
Starter motor checks
- EACH ONE OF THE FOLLOWING TESTS MUST BE PER-
FORMED FOR NOT LONGER THAN 3-5 SECONDS.
IF THIS WARNING IS NOT OBSERVED, THE COIL RECEIV-
ING A LONG-LASTING CURRENT, CAN BE BLOWN.
1. Thrust test
Disconnect the remote control cable.
Connect the battery negative (-) termi-
nal to the starter motor body and to the
remote control terminal.
ES - 98
Connect the positive (+) terminal to the
ST terminal. Make sure that the pinion
advances. If this does not occur, re-
place the remote control.
2. Pinion engagement upholding test
After having performed the test described above,
detach the remote control negative terminal. Make
sure that the guide pinion remains advanced.
If this does not occur, replace the remote control.
3. Pinion return check
After performing the pinion maintenance check,
disconnect the negative of the motor casing. Make
sure that the pinion is in the relevant housing. If
this is not met, replace the remote control.
4. Checking performance without load applied
Connect the battery to the starter motor by inter-
posing an ammeter as shown in the figure.
Make sure that the motor rotates regularly while
the pinion advances. Measure the current as in the
figure:
- CONNECT THE CABLE TO THE REMOTE CONTROL, BE-
FORE PERFORMING THE TEST.
Characteristic
Prescribed current:
less than 50 A at 11 V
ES - 99
Starter motor removal
Removal
1. Disconnect the cable from the remote control.
2. Remove the remote control fixing nut.
3. Remove the remote control.
4. Undo the two screws and then remove the sup-
port cap.
ES - 100
5. Using a thickness gauge, measure the rotor
shaft thrust clearance at the point between the lock
washer and the external cover.
Characteristic
Clearance:
0.05 - 0.60 mm
KEY:
1. Washer
2. Cover
3. Clearance
6. Remove the lock washer, the spring and the
rubber ring from the cover.
7. Remove the cover from the stator removing the through bolts.
8. With a pair of pliers, lift the springs and remove
the brushes from the relevant brush holder.
PAY ATTENTION NOT TO SCORE THE COMMUTATOR
WHEN REMOVING IT.
ES - 101
9. Remove the engaging lever from the rotor.
10. Remove the coil and the rotor.
11. Remove the retention collar from the circlip by
giving a few taps on the collar with a screwdriver.
12. Remove the circlip with a screwdriver.
13.Remove the collar.
ES - 102
14. Remove the coupling.
Verifiche e controlli
Rotor check
Rotor insulation check
Make sure that there is no continuity between the
commutator and the rotor coil: use an ohmmeter.
If there is continuity, replace the remote control.
Commutator continuity check
Check the continuity between each segment ad-
jacent to the commutator with an ohmmeter. If
there is no continuity among any of the adjacent
segments, replace the rotor.
Commutator check
1. Check for possible burning on each contact sur-
face of the commutator segments with the brush-
es. If surfaces are dirty or burnt, rectify with
abrasive paper (No. 400) or with a lathe.
ES - 103
2. Commutator eccentricity check
Hold the rotor by both sides on two V-shaped sup-
ports. Check the commutator eccentricity with a
dial gauge.
If the eccentricity exceeds the limits allowed, po-
sition the commutator on a lathe.
Characteristic
Eccentricity limit.
0.05 mm
3. Commutator diameter measurement
Measure the commutator diameter with a micro-
meter or a sliding gauge.
If the commutator diameter is shorter than the di-
ameter minimum, replace the rotor.
Characteristic
Standard diameter
28 mm
Minimum diameter
27 mm
4. Groove depth check. Measure the depth of in-
sulator grooves between the commutator seg-
ments
If the depth of insulator grooves is less than the
limit value, replace the commutator.
Characteristic
Minimum depth:
0.2 mm
KEY:
A=Grooves
B=Groove correction
C=Incorrect groove depth
D=Correct
E=Segment
ES - 104
Field winding check
1. Field winding continuity check. With an ohm-
meter, check the continuity between windings B
and C D.
In case there is no continuity, replace the brush
unit and/or windings. Field winding check.
2. Field winding short circuit test. With an ohmme-
ter, make the connection between the brush and
the relevant support. If there is continuity, replace
the brush unit and/or windings.
Inspection
Brush check
Brush length check
Measure the brush length, with a sliding gauge.
Brush replacement
If the length is shorter than the minimum value re-
quired, replace the brushes.
Characteristic
Standard length A:
16 mm
Minimum length B:
10.5 mm
ES - 105
Brush holder check
Brush holder insulation check
With an ohmmeter, measure the resistance be-
tween the positive and negative terminals of brush
holder A.
Brush holder replacement
If the resistance value is lower, replace the brush
holder.
Characteristic
Insulation resistance:
100 M or more
Coupling check
Checking the pinion gear tooth and grooves.
Check for possible damage to the pinion gear tooth
and grooves. If the tooth is damaged, replace the
coupling. Also check the flywheel crown gear for
signs of wear or damage.
Brush replacement procedure
1. Cut the brush braid (copper braid) from the ter-
minal side at point A shown in the figure.
KEY:
A= Cutting point
2. With a file or a similar tool, remove the welding
traces, in order to obtain the correct terminal sizes.
Prescribed sizes:
- PAY ATTENTION TO REMOVE THE MATERIAL AS INDI-
CATED IN THE SIDE FIGURE, SINCE THE PART TO BE
REMOVED IS VERY REDUCED AND IT IS EASY TO SCORE
THE FIELD WINDING.
Characteristic
Thickness:
1.3 - 1.5 mm
Width:
5 mm
ES - 106
KEY:
A= Cutting point
B= Brush
C= Section to be removed
D= Coil side end
3. Position the brush flat end on the braid side to
be welded (copper braid). Press with pliers both
side ends.
4. Weld the connection section. Rectify the section
with a file or similar tool, so that the section com-
plies with sizes, as indicated in the right figure.
- MAKE SURE THE BRAID POSITION IS CORRECT. - WHEN
WELDING IS PERFORMED, HEAT THE PART TO BE WEL-
DED. PAY ATTENTION THAT THE WELDING IS NOT ON
THE BRAID SIDE.
- MAKE SURE THAT THE WELDING ADEQUATELY FLOWS
INSIDE THE PLATE.
- MAKE SURE THAT THERE ARE NO WELDING DEPOSITS
IN THE FIELD WINDING.
Starter motor coupling check
Hold the coupling and rotate the pinion clockwise.
Make sure that it turns properly. Rotate the pinion
anticlockwise. Make sure that the pinion does not
turn. If this is not met, replace the starter motor
clutch.
Magnetic field check
1. Remote control
Cause the plunger to re-enter by pressing it with
your fingers. Releasing the plunger, make sure
that it returns immediately to its original position. If
this does not occur, replace the remote control.
ES - 107
2. Return coil check
With an ohmmeter, make sure that there is con-
tinuity between the ST and C terminals. If this does
not occur, replace the remote control.
3. Seal coil check
Always using an ohmmeter, make sure that there
is continuity between the ST terminals and the re-
mote control body. If there is no continuity, replace
the remote control.
Bearing check
1. Measure the inside diameters of the bushings,
transmission seat and the cover.
2. Measure the rotor bearing outside diameter.
ES - 108
3. Determine clearance by extracting the rotor
bearing outside diameter from the bushing inside
diameter.
If clearance exceeds the limit, replace the bushing.
The punch has a 15 mm outside diameter.
Characteristic
Clearance limit :
0.2 mm
Montaggio
Assembly
1. Fit the coupling on the rotor shaft.
2. Fit the collar on the rotor shaft.
- TO LUBRICATE BUSHINGS, USE GREASE FOR HIGH
TEMPERATURES.
3.Fit the circlip on the rotor shaft.
ES - 109
4. Give it a few taps with a screwdriver so that the
collar is fitted on the circlip.
5. Fit the engaging lever and the rotor in the trans-
mission seat.
- APPLY HIGH TEMPERATURE GREASE ON THE SLIDING
SECTIONS OF THE ROTOR SHAFT AND THE ENGAGING
LEVER.
6. Fit the stator.
7. Fit the brush holder on the rotor shaft.
8. Keeping the springs lifted with pliers, refit the 4
brushes on the relevant support.
9. Fix the commutator cover to the stator coil as-
sembly with the two through bolts.
ES - 110
10. Fit the rubber ring, brake spring and the safety
plate in the respective order on the rotor shaft
11. Position and fix the rear cover with the two
screws.
12.Refit the remote control in the relevant housing,
while paying attention to hook the remote control
to the control lever. Finally, lock the remote control
with the 2 screws.
13. Connect the cable to the remote control.
Installazione sul veicolo
Installation
Once removal and fitting operations are finished, perform function controls and, afterwards, fit the starter
motor on the vehicle.
Alternator
Recharge system
ES - 111
This section of the manual provides information to check the correct operation of the recharge system.
Removal and fitting operations are also described.
Before performing checks on the vehicle,
check the following:
Battery electrolyte density
Battery terminal fitting and check
V-belt tension
Fuse
Cable harness
Abnormal noises emitted by the alter-
nator with engine running
Test of delivered power without electric charge
applied.
1. Make sure that all the switches are off to avoid
applying unnecessary electric charge.
- Headlamps
- Heating system
- Car radio
- Defroster
- Cab internal lights, etc.
2. Gradually increase engine revs up to 2500 rpm.
Then, measure voltage and current.
N.B.
- IMMEDIATELY AFTER THE ENGINE IS STARTED, THE
CURRENT EXCEEDS 10 AMPERE. THIS IS CONSIDERED
NORMAL.
Characteristic
Current:
not exceeding 10 A
Voltage:
14.2-14.8 V
ES - 112
- If the voltage detected was lower than that speci-
fied, earth the "F" terminal as indicated in the side
figure. Then start the engine. If voltage increases,
replace the regulator. If instead, voltage shall re-
main below that specified, it is necessary to check
alternator.
Test of delivered power with electric charge
applied.
1. To apply electric charge, operate as follows.
Turn the high-beam headlamps on.
Set the heater fan to the maximum
speed, to "hot".
2. With the engine at 2500 rpm, check the output
current.
- WITH THE BATTERY COMPLETELY CHARGED, IT IS
POSSIBLE THAT THE CURRENT IS BELOW TO THAT DE-
SCRIBED ABOVE: THIS IS CONSIDERED NORMAL. NOW,
INCREASE THE ELECTRIC CHARGE, FOR EXAMPLE, AC-
TIVATING THE REAR DEFROSTER. THEN CHECK IF THE
DELIVERED CURRENT INCREASES OR NOT.
Characteristic
Specified value:
20 A or more
ES - 113
Componenti
KEY:
1.Alternator assembly
2. Pulley fixing nut
3. Alternator pulley
4. Spacer
5. Transmission side cover
6. Stud bolt
7. Bearing
8. Fixing plate
9. Alternator rotor unit
10. Bearing
11. Dust guard
12. Rectifier side cover
13. Rectifier support
14. Regulator unit
15. Brushes
16. Spring
17. Brush holder
ES - 114
18. Rear cover
Rimozione dal veicolo
Removal
1. Disconnect the battery negative (-) terminal.
2. Remove the terminal clamps (+) B, IG and L of
the alternator.
3. Undo the alternator fixing bolts.
4. Remove the V-belt.
Removal
Removal
1. Undo the nut fixing the alternator pulley.
2.Remove the spacer.
N.B.
- USE A PNEUMATIC GUN TO PERFORM THIS OPERA-
TION.
3. Rear cover removal
Remove the nut and the insulator.
Undo the three screws.
Remove the rear cover.
4.Remove the brush holder.
ES - 115
5. Remove the regulator unit.
6. Rectifier support removal.
Unscrew the fixing screws.
Straighten the stator cable.
Remove the rectifier support.
7. Loosen the nuts and the bolts and remove the
rectifier support housing.
ES - 116
8.Remove the rotor.
Check
Rotor
Rotor check - (for circuit opening).
Using an ohmmeter, check resistance between
the commutator rings.
If this does not result, replace the remote control.
Characteristic
Standard resistance:
2.9 0.2
Rotor check - (for ground).
Make sure there is no continuity between the com-
mutator rings and the rotor casing.
If there is, replace the rotor.
Commutator check.
1. Check the commutator surface for irregularities
(e.g. wear, burning etc.); then replace the rotor.
ES - 117
2. with a gauge, measure the commutator outside
diameter.
If the commutator outside diameter is shorter than
the minimum value requested, replace the rotor.
Characteristic
Standard diameter
14.4 mm
Minimum diameter
14 mm
Stator
Stator check - (for circuit opening).
With an ohmmeter, check if there is continuity be-
tween the stator coil terminals. If there is no con-
tinuity, replace the stator assembly.
Characteristic
Specified resistance:
around 0.2
Stator check - (for short circuit).
Using an ohmmeter, check if there is any condition
present that could cause a short circuit between
the coil cables and the casing cables. If there is
continuity, replace the stator.
Brush and brush holder
Brush protrusion length check.
With a gauge, measure the brush protrusion
length.
If the length measured is shorter than the minimum
length specified, replace the brushes.
Characteristic
Standard length:
10.5 mm
Minimum length:
1.5 mm
ES - 118
Brush replacement (if necessary).
1. With a welder, take the pre-existent welding to
the melting point, so as to remove the brushes and
the springs from the relevant support.
N.B.
- IT IS NECESSARY TO REMOVE THE COAT OF PAINT
FROM THE WELDING SURFACE BEFORE CARRYING OUT
THE OPERATION.
- USE A WELDER WITH A POWER OF ABOUT 40 W FOR
THIS OPERATION.
2. With the spring placed in the relevant housing,
fit the braid in the brush holder.
N.B.
- REMOVE THE WELDING MATERIAL FROM THE BRUSH
HOLDER SO THAT THE METAL BELOW CAN BE SEEN.
3. Weld the brush wire in the brush holder so that
the part exposed complies with the specified
length.
N.B.
- TO FACILITATE THE WELDING OPERATION: INSERT
THE WIRE IN THE BRUSH HOLDER AND POSITION THE
PART EXPOSED ACCORDING TO THE SPECIFICATION.
BEND THE FRONT PART OF THE WIRE ON WHICH THE
WELDING MATERIAL IS APPLIED, THEN WELD THE WIRE
TO THE BRUSH HOLDER.
Characteristic
Standard length:
10.5 mm
4. Make sure that the brush moves freely in the
brush holder.
ES - 119
5. Cut possible wire surplus material and spread
insulating varnish.
Rectifier check - (positive + side).
1. Using an ohmmeter, connect a probe to the rec-
tifier positive terminal; Alternatively, connect the
other probe to each one of the other rectifier neg-
ative terminals.
2. Repeat the same operation inverting the 2 ohm-
meter probes.
3. Make sure there is continuity only in one of the
two tests.
If continuity is detected in both tests, replace the
rectifier support.
Rectifier check - (negative - side).
1. With an ohmmeter, connect one of the two ohm-
meter probes to each rectifier negative terminal
and connect the other probe to each rectifier pos-
itive terminal.
ES - 120
2. Repeat the same operation described above re-
versing test polarity.
3. Make sure there is continuity only in one of the
two tests. If continuity is detected in both tests, the
rectifier support should be replaced.
Rear bearing check.
Make sure that the rear bearing turns freely.
Otherwise, replace the bearing.
Rear bearing replacement (if necessary).
1. Remove the rear bearing and relevant dust
guard from the rotor, using and extractor for bear-
ings.
N.B.
- PAY SPECIAL ATTENTION NOT TO DAMAGE THE RO-
TOR DURING THE OPERATION.
2. With a hydraulic press, refit the bearing with the
relevant spacer.
3. Using an adequate section of tube, fit a new
bearing cover.
ES - 121
Front bearing check.
Make sure that the bearing turns freely. Otherwise,
replace the bearing.
Front bearing replacement (if necessary).
1. Undo the four screws and remove the fixing
plate.
2. With a press and using a box-spanner, remove
the bearing and the relevant housing.
3. With a press, place the new bearing in the rel-
evant housing.
ES - 122
4. Refit the plate with the 4 screws.
Refitting
Assembly
1. Fit the rotor in the relevant housing.
2. Refitting the rectifier housing cover.
Fit the rectifier housing cover by using two bolts
and nuts.
- PAY ATTENTION NOT TO DAMAGE THE STATOR CA-
BLES DURING REFITTING.
- IF FITTING TURNS OUT DIFFICULT, SLIGHTLY PRESS BY
TAPPING WITH A PLASTIC HAMMER.
3. Refitting the rectifier support, regulator and the
brush holder.
Fix the rectifier support to the cover,
with the stator coil wires passing
through the rectifier support holes.
ES - 123
Wind up the coil wires around the rec-
tifier fixing screws.
Tighten the 4 screws.
4. Fit the regulator with the three fixing screws.
5. Refit the brush holder so that the distance be-
tween the brush support and the regulator is: 1 mm
Lock the brush holder with the 2 screws.
ES - 124
6. Rear cover refit.
fix the rear cover with the three screws.
Position the insulating terminal and
lock it with the relevant nut.
7. Fixing the pulley to the alternator shaft.
Use a box wrench and a bushing (Beta 720 type).
Generator - Pulley 80
8. Lock the specific tool C in a vice.
Tighten the nut by turning the specific tool B.
Generator shaft fixing nut: 110
9. Remove the specific tools.
10. Make sure that the rotor turns freely.
ES - 125
Installazione sul veicolo
Installation
1. Temporarily fit the alternator to the engine with
two fixing bolts.
2. Fit the alternator belt.
3. Regulate the belt bending so that, by applying a
pressure equivalent to 98 N (10 kg-f), at the central
point between the water pump pulley and the al-
ternator pulley, this results as follows
4. Fix cable B (+) and the alternator connector.
5. Reconnect the ground lead terminal to the bat-
tery negative (-) terminal.
N.B.
- A NEW BELT IS A BELT WHICH HAS BEEN USED LESS
THAN 5 MINUTES.
Characteristic
Bending:
New belt: 5.0-7.0 mm
Belt used: 6.0-8.0 mm
Power lock
Air filter
CENTRAL LOCKING WITH REMOTE CONTROL
SYSTEM DESCRIPTION
The Piaggio system 612697 is an electronic device which allows the simultaneous activation of vehicle
door locks (central locking). The central locking, can be activated in two different modes:
- Manual - Radio-controlled
The activation of the central locking via remote control is signalled by a differentiated switch-on of the
turn indicators. For central locking of locks, the Piaggio device 612697 is equipped with a remote control
working via radio with a frequency type-approved to operate at 433.92 Mhz. A safety device integrated
to the system blocks central locking activation with the remote control while the vehicle is moving.
ES - 126
TECHNICAL CHARACTERISTICS OF THE SYSTEM
Rated supply voltage: 12 Volts
Supply voltage range: 11-18 volt
Electric current requirement at 13.5 V: 4 mA
Locking relay maximum capacity: 30 Amp
Turn indicator relay maximum capacity: 8 Amp
Module output maximum capacity: 50 mA
REMOTE CONTROL
Transmission frequency: (TUV AUSTRIA type-approved frequency): 433.92 Mhz
Free field capacity: 20 m
ELECTROMECHANICAL ACTUATORS:
Rated supply voltage: 12 Volts
Supply voltage range: 11-15 Volts
Electric current requirement at 13.5 V while blocked: 5 Amp
Schemi elettrici e di principio
KEY:
1. Door locking control unit
ES - 127
2. Remote control
3 Turn indicators
4. Front right actuator
5. Electrical contacts for sliding doors
6. Rear right actuator
7. Rear left actuator
8. Front right actuator
9. Remote controls autodetection
10. Fixed power supply
11. Ignition key
12. Live positive
N.B.
IN DIESEL ENGINE VEHICLES, THE LIVE DEVICE CONNECTION WIRE IS BLACK.
ES - 128
Settaggio dei parametri e manutensione
NEW REMOTE CONTROL DETECTION
The central locking system, to work by means of
remote control, must learn the transmission code.
When the vehicle is purchased, the system is pro-
vided with a remote control already working. If the
customer wants a second remote control or looses
the original one, it is necessary to perform a new
transmission code detection procedure. To per-
form this operation correctly, strictly follow the in-
structions indicated below.
New remote control detection procedure:
Open the glove-box cover.
Remove the screws fixing the glove-box. The po-
sition of screws is shown in the following figures.
Remove glove-box extracting it from the instru-
ment panel.
Identify, the door locking control unit in the glove-
box.
Remove the door-locking control unit from its
seat so as to be able to reach the cable harness
to which it is connected.
Identify in the cable harness, a white wire with a
free end.
Remove the insulating cap from the free end of
the wire.
Connect the white wire A to the red/white wire
connected to the door locking control unit.
the vehicle turn indicators flash four times indi-
cating that the detection procedure has started.
From this time on, the procedure is differentiated
according to the vehicle engine.
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Procedure
Start the engine.
The turn indicator bulbs remain stead-
ily on.
Stop the engine.
The turn indicator bulbs turn off.
Press the remote control button to be
learnt.
The turn indicator bulbs flash one time
confirming the remote control detec-
tion.
Disconnect the white wire A in the con-
trol unit from the white/red wire.
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The turn indicator bulbs flash one time
indicating that the procedure has fin-
ished.
Refit the insulating cap on the white
wire.
Final operations:
Once the insulating cap on the white
wire is refitted, reinstall the door lock-
ing control unit in its original seat.
Refit the glove-box in its original seat
and fix it with the corresponding
screws.
SYSTEM MAINTENANCE
In order to maintain the central locking system, it is necessary to adopt some simple tactics, listed below:
REMOTE CONTROL:
Recommendations of use:
The system remote control does not require par-
ticular tactics for its working. As every electronic
device, avoid exposing it to violent shocks, ex-
tremely high temperatures and immersing it in any
type of fluid. Remember that, on summer days, the
instrument panel of vehicle can get significantly
hot if it is exposed to the sun.
Battery replacement:
For its operation, the remote control uses alkaline
batteries. Batteries are subject to a gradual loss of
their charge with the regular use of the remote
control. The more the remote control is used the
faster the batteries will be discharged. To prevent
failures of the central locking operated by remote
control, the latter has inside a device that indicates
the battery charge status. When using the remote
control regularly, press the control switch and the
green transmission LED turns on to remain stead-
ily on. In case the battery charge status should
decrease below the standard level in order to guar-
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antee the control proper operation, by pressing the
control switch, the green transmission LED turns
on flashing, warning the user that it is necessary a
battery replacement.
CAUTION
TO PLACE THE NEW BATTERIES INSIDE THE REMOTE
CONTROL, REFER TO THE FIGURE. BATTERIES TO BE
USED ARE TYPE CR1616. THE USE OF DIFFERENT BAT-
TERIES FROM THOSE RECOMMENDED COULD CAUSE
IRREPARABLE DAMAGE TO THE REMOTE CONTROL. DO
NOT DISPOSE OF DISCHARGED BATTERIES IN THE EN-
VIRONMENT, USE THE APPROPRIATE CONTAINERS.
Characteristic
Battery type:
CR1616
ELECTRICAL CONTACTS FOR SLIDING
DOORS:
Contact maintenance:
The contacts of sliding doors allow the central
locking system to control locks from the doors.
Check the contact plate status periodically for
traces of dirt or oxide. To clean these devices, use
a cloth soaked in alcohol. Do not use abrasive ma-
terial.
SYSTEM PROTECTION FUSE:
Fuse replacement:
If the system stops working in manual mode as
well as in the radio operated mode, check if the
system protection fuse A is in proper conditions.
For this check, it is necessary to remove the fuse
box board, located under the instrument panel
close to the pedal assembly, removing the two fix-
ing screws.
Modello GEMINI
ALARM SYSTEM AND CENTRAL LOCKING
GEMINI 7563 MODEL
Introduction
The unit 7563 is a module operated by radio comprising a self-powered alarm control unit and an
external sound unit, that can be used on vehicles without original radio control and a 12V battery.
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IN ORDER TO CARRY OUT THE DIFFERENT FITTING PROCEDURES PROPERLY, CAREFULLY
CHECK ALL THE ELECTRICAL CONNECTIONS REQUIRED, PAYING SPECIAL ATTENTION TO
BASIC CONNECTIONS:
DEVICE POWER SUPPLY (POSITIVE AND GROUND).
LIVE POSITIVE (+15/54)
DOOR SWITCH.
BONNET OR TRUNK SWITCH.
Functions
Alarm system activation/deactivation through rolling code radio remote controls (random
rolling code).
Passive activation function (programmable).
Visual signalling (blinker).
Sound alarms (programmable).
Perimetric protection.
Volumetric protection (excludible during the activation phase).
Central locking, electric windows and roof (for vehicles equipped with "Pack-comfort" sys-
tem).
Engine electrical locking.
Current absorption sensor (programmable).
Alarm memory by means of visual signalling/sound alarms.
"PANIC" or "CAR-FINDER" function.
Emergency deactivation of the system through the pin-code.
Negative control for additional, self-powered siren and pager.
Anti-hijack function.
Garage function.
GEMINI 7563.01: Similar to 7563 without electronic key.
GEMINI 7562: Similar to 7563 but not self-powered.
GEMINI 7562.01: Similar to 7562 without electronic key.
GEMINI 7561: Similar to 7562.01 without engine block and control for additional or self-powered siren.
OPERATION DESCRIPTION
1. Alarm total activation
Press key No. 1 (stippled) of the radio control or insert the electronic key in the appropriate hole.
A sound alarm by the siren and a visual signal by the turn indicators confirm the operation.
The alarm has a pre-activation "neutral period" which lasts 45". During the first 25" of this period, the
sensors can be excluded as described in the relevant section.
2. Activation without siren sound
This function allows users to activate the alarm system without the siren sound in case of a car break-
in is attempted.
To exclude the siren, follow the instructions given below:
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Turn the ignition key to "ON"; the status LED comes on for 0.5 seconds.
During this period, press key No. 2 of the radio control.
Leave the vehicle and press key No.1 of the radio control.
The alarm is activated with light and sound signals, as previously described, which are not
activated in case of a break-in attempt.
THE SIREN SOUND EXCLUSION IS LINKED TO EACH SINGLE ACTIVATION CYCLE. WE REC-
OMMEND THIS FUNCTION TO BE APPLIED WHEN NEAR HOSPITALS.
3. Activation without sensors and comfort control
This function allows userS to activate the alarm system without external sensors and comfort control.
The exclusion concerns any wire sensor connected to the alarm system (ultrasounds, super-high fre-
quency, impact).
Besides, if volumetric sensors via radio are installed via radio (section 7709), the following procedure
also includes such sensors.
Press key No. 1 of the radio control and, during the first 25" of the activation neutral period, press key
No. 2 of the radio control.
Following such operation, the turn indicators flash once and the sensors are subsequently excluded.
N.B.
THE PROCEDURE DESCRIBED ABOVE IS LINKED TO EACH SINGLE ACTIVATION CYCLE.
4. Alarm activated
Once the neutral period has finished (approx. 45 seconds), the system is "armed", or rather ready to
detect a break-in attempt.
The LED flashes intermittently to signal that the system is completely armed.
Any break-in attempt is signalled when the alarm with light/sound alarms is deactivated (see the relevant
section).
5. Alarm, neutral period and alarm cycles
As previously described, break-in attempts are signalled by the system with light/sound alarms.
Once the alarm cause is over, before another possible warning, there is a "neutral period" of 5 seconds,
useful to deactivate the system using a pin-code.
The alarm causes have a limit of 5 cycles, lasting 30 seconds each, for each entry and each activation
cycle.
The only alarm causes which are unlimited are the starting attempts (live positive, +15/54) and the cable
cut.
THE ALARM CYCLE CAN BE INTERRUPTED, WITHOUT DEACTIVATING THE SYSTEM, BY
PRESSING KEY No. 2 OF THE RADIO CONTROL.
6. Alarm deactivation
Press key No. 1 of the radio control and insert the electronic key in the appropriate hole. The turn
indicators flash three times and the siren sounds three times to signal deactivation.
If an alarm condition is detected, the turn indicators flash five times and the siren sounds five times. For
causes and related warnings, see the relevant section.
7. Emergency deactivation with pin-code
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This function allows users to deactivate the device if the radio controls do not work or are lost.
The PIN-CODE provided comprises four numbers between 1 and 9. These digits, with 1-1-1-1 as the
factory default code, are the same in all the alarms of 7563 series and similar. For safety reasons,
change the code, by personalising it with a code chosen by the user.
For the new pin-code program specifications follow the indications contained in the relevant section
(page 12).
8. Alarm memory
If the turn indicators flash five times and the siren sounds five times when the alarm is deactivated,
thanks to the LED memory, the cause which has generated the last alarm condition can be identified.
To do so, turn the starter key to "ON" and watch the status LED, which starts flashing, indicating the
last cause of alarm. The visual signal will be repeated for 5 times and can be interrupted simply by
turning the starter key to "OFF".
The possible alarm warnings are indicated in the following diagram.
LED WARNING
*O* Absorption sensor (5 cycles)
**O** Start-up tried (+15/54) (infinite cycles)
***O*** Door switch (5 cycles)
****O**** Cable cut (infinite cycles)
*****O***** External wire sensor bonnet/trunk switch (5 cycles)
******O****** Magnetic contact via radio (5 cycles)
*******O******* Infrared sensor via radio (5 cycles)
*= ON - 1 second
O= OFF - 2 seconds
Garage function.
This function is useful if it is necessary to deactivate the alarm, for example, due to maintenance, without
intervening on the programming performed.
In fact, this function deactivates the alarm completely without activating the anti-distraction function and
passive function.
To do so, follow the short procedure described below:
With the alarm deactivated, turn the ignition key to "ON".
The LED turns on for a short time (0.5 ").
During that period, insert the electronic key in the appropriate hole.
The LED turns off, indicating the alarm deactivation.
To restore the regular functions, activate the alarm with the radio control.
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ALARM AND CENTRAL LOCKING
1. Emergency key
2. Super-high frequency module
3. Alarm positive activated
4. To the central locking
5. To the door and case switches
6. To the bonnet switch
7. To the turn indicators
8. To the switch
9. To the engine block device (Only for models 7563 and 7562)
10. Additional or self-powered siren (Only for models 7563 and 7562)
11. Ground
12. Battery (Only for models 7563 and 7562)
13. To the tone wheel
14.Aerial
15. Control unit
Electrical connections
In vehicles equipped with catalytic converter, carry out the engine locking on the fuel pump.
Connect the power supply positive of the system 7563 to vehicle battery positive pole or to
its shunt.
Connect the power supply negative of the system 7563 to the vehicle metal frame.
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Always connect the GREEN/BROWN wire of the module to the vehicle door switches.
Always connect the GREEN wire of the module to the vehicle bonnet switch.
Always carry out the electrical connections, then any programming of the module.
For central locking connections refer to the diagrams shown in the following pages.
The table shown below refers to the alarm cable harness wiring diagram on the next page.
Before carrying out all the electrical connections, detach the battery negative pole and reconnect it only
when the fitting has finished.
IN THE ALARM CABLE HARNESS, THERE ARE 2 TWO-WAY CONNECTORS FOR THE CON-
NECTION OF THE ELECTRONIC KEY HOLE AND RELEVANT LED. THE 4-WAY CONNECTOR IS
USED FOR THE ULTRASOUND OR SUPER-HIGH FREQUENCY MODULE CONNECTION.
N.B.
FOR THE AVAILABLE DIAGRAMS OF EACH SINGLE VEHICLE, CONTACT AN AREA DEALER.
Ultrasound module connection and position-
ing
Connection is simple since, the connector corre-
sponding to that present in the ultrasound module
is fitted in the alarm cable harness.
J oin the 4-way connector of the alarm cable har-
ness to the 4-way connector of the ultrasound
module.
Fit the WHITE connector matching the word RX on
the ultrasound module.
Fit the RED connector matching the word TX on
the ultrasound module.
Install the ultrasound sensor transducers at the
highest point of the internal posts of the front wind-
shield, far from the air conditioner ventilation.
KEY:
1. Red connector
2. Ultrasound module
3. White connector
4. Transmission
5. Reception
Ultrasound sensor adjustment
In case you do not wish to activate the diagnosis,
proceed as described below:
With the alarm deactivated, lower the
vehicle front glass about 20 cm.
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Adjust the trimmer located on the ul-
trasound module.
Activate the alarm and wait for the end
of neutral activation time with doors,
bonnet and trunk closed.
Introduce a foreign matter in the vehi-
cle cab and shake it; The LED inserted
in module 5123 turns on (in addition to
the siren sound) to signal the matter
detection.
If sensitivity is not correct, adjust the
trimmer again and repeat operations
from the start.
If the adjustment carried out is correct,
position the module 5123 definitively.
Super-high frequency module connection and
positioning
Connection is simple since, the connector corre-
sponding to that present in the ultrasound module
is fitted in the alarm cable harness.
J oin the 4-way connector of the alarm cable har-
ness to the 4-way connector of the super-high
frequency.
The sensor operates based on the principle of re-
flection of the high-frequency electromagnetic
waves by conductive objects (metals, human
body, etc.).
Measuring the magnitude of these reflections al-
lows detecting any foreign object moving within the
electromagnetic field, thus causing an alarm sta-
tus.
The characteristics of sensor 7059 render it unaf-
fected by air fluctuations (for example: wind, tur-
bulence, thermal variations, etc.), therefore it is
particularly suitable to be fitted on cabriolet vehi-
cles or vehicles with sunroof.
Permeability to electromagnetic waves of non-
conductive materials (plastic, fabrics, etc.) permits
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installing sensor 7059 under the cab panelling,
and therefore it is completely out of sight.
THE SENSOR MUST BE ALWAYS FIXED AT A CENTRAL
POSITION WITH RESPECT TO THE VEHICLE AXIS, WITH
THE SIDE SHOWING THE WORDS AND THE ADJUST-
MENT TRIMMER FACING THE VEHICLE INTERNAL
SPACE.
KEY:
1. Sensitivity adjustment
2. Alarm indicator LED
Super-high frequency sensor adjustment
In case you do not wish to activate the diagnosis, proceed as described below:
Adjust the trimmer to a maximum sensitivity position (turning it clockwise to maximum).
Activate the alarm and wait for the end of neutral activation time with doors, bonnet, trunk
and windows of the vehicle closed.
Move the hands close to the vehicle windows (side windows, windshield and rear window)
checking that the sensor 7059 does not detect anything.
If alarm conditions are detected, it is necessary to reduce the sensor sensitivity. Turn the
adjustment trimmer anticlockwise, then repeat the test as indicated above.
If sensor operations are not detected, deactivate the alarm and lower one of the front win-
dows of the vehicle.
Activate the alarm again and introduce a foreign matter inside the cab, simulating a theft
attempt.
If the alarm intervenes only after the introduction of the foreign body in the cab, adjustment
has been carried out correctly.
Diagnosis
ACTIVATING THE DIAGNOSIS PROCEDURE THE ALARM RETURNS TO THE INITIAL STATUS,
AS PROGRAMMED BY GEMINI. THEREFORE, CARRY OUT A POSSIBLE DIAGNOSIS TEST BE-
FORE PROGRAMMING OR CHANGING THE PIN-CODE (SEE THE USER MANUAL). TRANSMIT-
TERS, ELECTRONIC KEYS, TAG CARDS, MAGNETIC CONTACTS AND INFRARED SENSORS
PREVIOUSLY STORED ARE NOT DELETED.
For a correct check of connections, sensors or control peripherals, turn off any TAG cards near the
vehicle on which the test is being carried out.
In fact, the TAG periodic transmission could distort the different tests.
To activate the procedure, follow the instructions given below:
Remove the alarm power supply.
Press and hold the LED status key or short-circuit the RED and BLACK cables of the two-
way connector to connect the LED.
Power the alarm.
Once the alarm is powered, the 4 sound alarms and 4 turn indicator flashes, indicate that
"diagnosis" has started.
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By opening one door of the vehicle, the siren is activated for all the time during which the
door is open, while by opening and closing the door again the siren is activated for a period
of about 2".
In both cases, once the siren sound alarm has finished , there is a turn indicator flashing
and a sound signal.
By activating any other device, at each alarm reception, or in case of signals coming from
electrical connections (e.g. bonnet switch) there is a turn indicator flashing and a sound
signal.
Release the status LED switch or remove the short-circuit carried out previously.
The alarm indicates the end of the diagnosis procedure with a sound alarm and a turn indicator flashing.
Control for self-powered siren/pager
The alarm control unit has the command to use an additional siren with the Yellow-Black wire (there is
no negative lead during the alarm activation). In case it is desired to reverse the command (there is a
negative lead during the alarm activation) follow the operations described below:
With the alarm not powered, turn the starter key to "ON".
Power the control unit.
Take the starter key back to "OFF".
TO REVERSE THE COMMAND AGAIN, IT IS NECESSARY TO REPEAT THE OPERATIONS PRE-
VIOUSLY DESCRIBED. CHECK THERE IS A NEGATIVE LEAD DURING THE ALARM ACTIVATION
TO CONNECT THE PAGER.
Programmable functions
1. Sound alarms
This function allows the user to exclude all the sound alarms permanently. For programming see the
relevant paragraph.
2. Panic alarm or car-finder
The PANIC ALARM function allows the user to activate the visual signalling/sound alarms intentionally,
simply by pressing key No. 2 of the radio control independently of the alarm status.
The alarm warning lasts for about 30", and it is possible to stop such warning by pressing key No. 2 of
the radio control again.
During the alarm warning, the status LED remains steadily on.
If during the programming phase the PANIC function is disabled, the "CAR FINDER" is activated.
This function allows, only with the ALARM ACTIVATED, to obtain a short visual signalling/sound alarm
by pressing key No. 2 of the radio control. Such function is useful in case it is necessary to trace the
vehicle inside a car park, without causing useless alarm conditions.
The visual signalling/sound alarm comprises a siren grave tonality and simultaneous turn indicator
flashing.
SOUND ALARM EMISSION IS SUBJECT TO THE ENABLING OF ALARMS DURING THE PRO-
GRAMMING PHASE OF ACCESSORY FUNCTIONS.
3. Current absorption sensor
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CAUTION
BEFORE ENABLING THE ABSORPTION SENSOR, CHECK REGULATIONS IN FORCE REGARD-
ING (NOISE POLLUTION).
By enabling the absorption sensor, there is an alarm warning at each minimum voltage variation inside
the electric circuit of the vehicle (e.g. bulb lighting).
4. Anti-distraction activation and door lock closing
This function determines the reactivation of the system if, after deactivating it, doors do not open within
a period of 35 seconds.
The function prevents leaving the vehicle unprotected if, after activating the protection system, key No.
1 of the radio control is pressed unintentionally, deactivating in this way the system.
The automatic activation is signalled by standard visual signalling/sound alarms (a turn indicator flashing
and a sound alarm) .
Activating the anti-distraction function comprises the activation of the central lock closing control.
THE FUNCTION IS CANCELLED WHEN OPENING A DOOR AFTER DEACTIVATION. THE CLOS-
ING OF LOCKS OF THE VEHICLE IN RUNNING ORDER IS AUTOMATICALLY ACTIVATED TO-
GETHER WITH THE FUNCTION PREVIOUSLY DESCRIBED.
After closing all the doors of the vehicle, turn the ignition key to "ON"; the vehicle locks are locked after
20".
Turn the key to "OFF" to open the vehicle locks automatically.
To avoid activating this function unintentionally, the system continuously monitors the panel key status
and the DOOR SWITCHES input line does not allow lock activation if, during the engine start-up (or
within the 20 seconds after start-up), the DOORS or the TRUNK OF the vehicle are manually opened.
5. Passive activation
The passive activation allows the alarm system to activate autonomously after 45" from the time the
vehicle is shut off.
To activate this function, after its programming, turn the ignition key to "OFF".
The alarm signals the activation of the passive function by means of the turn indicator flashing for a
long time, the status LED flashing two times and two sound alarms.
When a door of the vehicle is opened during the activation of the passive function, the activation time
count is reset, which is signalled by the LED which turns on and remains steadily on; the 45" count
continues when the door previously open is closed again.
6. Locking time
The alarm has an original locking time set to 0.5". If the vehicle requires a locking time of 6", change
such time in the programming phase.
IF THE COMFORT FUNCTION IS ACTIVATED, LEAVE THE LOCKING TIME SET TO 0.5" . IN FACT,
BY LEAVING A LOCKING TIME OF 6" ENABLED, THE WINDOWS OF THE VEHICLE OPEN WHEN
THE ALARM IS DEACTIVATED.
7. Comfort control
The comfort control automatically sets the closing of the vehicle windows when the alarm is activated.
In fact, the moment in which the function is activated, each time the alarm is activated, a 25" locking
control is also set on motors/control units which control the vehicle window rise.
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8. Central locking opening double pulse
By enabling this function, a double control pulse on the opening of locks is obtained, each lasting 0.5"
when the system is deactivated.
This allows unlocking the central locking on the vehicle having differentiated modes of opening doors
(first pulse to open the driver side door, second pulse to open the other doors).
The function is active only if the opening/closing time is set to 0.5 seconds, while setting the opening/
closing time to 6" automatically removes the double pulse.
System programming
The 7563 has a "basic configuration"; that is, a programming set by Gemini during manufacture, which
can be modified according to needs.
During programming phases, press key No.1 (stippled) of this control radio to enable functions, press
key No. 2 (plain) to disable them.
PAY ATTENTION NOT TO CHANGE ANY PROGRAMMING SET DURING FITTING.
To change programming, proceed as described below:
When the system is deactivated, open and keep the vehicle driver side door open.
Turn the starter key to "ON".
The status LED turns on for 0.5 seconds. during that time, press both radio control keys at
the same time.
The confirmation that programming has started is signalled by two sound alarms, a high-
pitched one and a grave tone one, besides the LED which turns on and remains on.
Refer to the table below to enable/disable functions, bearing in mind that, each time a radio
control key is pressed, the module moves on to the following function.
Sound alarms
Status: enabled
Key 1: enables
Key 2: disabled
Panic alarm or ''car-finder''
Status: panic alarm enabled
Key 1: enables panic alarm
Key 2: ''car finder'' enabled
Current absorption
Status: disabled
Key 1: enables
Key 2: disables
Anti-distraction, lock automatic closing
Status: disabled
Key 1: enables
Key 2: disables
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Passive activation
Status: disabled
Key 1: enables
Key 2: disables
Locking time selection
Status: 0.5'' selected
Key 1: enables 6''
Key 2: enables 0.5''
25 second control for comfort locking
Status: disabled
Key 1: enables
Key 2: disables
Double pulse during opening
Status: disabled
Key 1: enables
Key 2: disables
BY TURNING THE KEY TO " OFF" AT ANY MOMENT OF THE PROGRAMMING PROCEDURE,
PROGRAMMING IS FINISHED, LEAVING THE SUBSEQUENT FUNCTIONS UNCHANGED.
ONCE THE LAST FUNCTION IS PROGRAMMED, THE SYSTEM INDICATES THAT THE
PROCEDURE HAS FINISHED WITH TWO GRAVE TONE SOUND ALARMS AND ONE
HIGH-PITCHED SOUND ALARM, PLUS THE FACT THAT THE LED COMES OFF.
TURN THE IGNITION KEY TO "OFF".
ANTI-HIJACK FUNCTION
For safety reasons and so that the anti-hijack function can intervene with the vehicle running,
keep the TAG card separately from the radio control (generally paired with the vehicle ignition
key).
THE ANTI-HIJACK FUNCTION ACTIVATION MEANS ONLY THE RADIO CODE PROGRAMMED IS
RECEIVED AND SENT BETWEEN THE TAG AND THE MODULE 7563 BUT NOT THAT THE VE-
HICLE IS IMMOBILISED.
The module 7563 is equipped with an anti-hijack function, able to immobilise the vehicle in case of
assault and theft damaging the owner. The operation principle is based on the use of an automatic
transmitter, named TAG, which communicates with 7563 module through a radio code signal. When
the signal is not received by the TAG anymore, the module is activated, locking the vehicle as described
in the following chapters.
CAUTION
CONNECT THE BROWN/GREEN CABLE TO THE DOOR SWITCH SO THAT THE ANTI-HIJACK
FUNCTION OPERATES CORRECTLY.
1. ignition device
Press the TAG button for at least 3 seconds; the LED remains steadily on for all the time the key is
being pressed and held. During regular operation, a short flashing of the status LED of 3 seconds signals
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the TAG "ON" status. The identification code is periodically sent to the device fitted on the vehicle and
when the system receives it, a short flashing of the status LED signals the reception.
2. Device turnoff
Press the TAG button until the LED turns on and remains steadily on. After three short warning flashes,
the device turns off.
3. Vehicle start-up
Start the vehicle (ignition key set to "ON"). Il 7563 waits for two minutes a TAG transmission; if a trans-
mission is detected the anti-hijack function is activated. Otherwise (if the TAG does not come on and
therefore there is no transmission to the module 7563), the anti-hijack function does not activate. This
automatic procedure allows the safe use of the vehicle if the user does not carry the TAG, or the device
does not work due to a failure or due to exhausted batteries.
4. Assault with the vehicle running and vehicle theft
FOR CORRECT OPERATION, IT IS ASSUMED THAT THE VEHICLE HAS BEEN TAKEN AWAY
FROM THE USER WHO CARRIES THE TAG.
Once the door is open and walking away from the TAG, the module looses the radio contact with it,
after 16 seconds once the door is open, the vehicle prepares for pre-immobilisation mode. The LED
alarm system turns on and remains steadily on to signal this status. In this situation note that, for safety
reasons, the vehicle running is still not influenced. After 1 minute the door is open, the module activates
the vehicle immobilisation as described in subsequent paragraphs (in addition to the siren that sounds
for 2 minutes).
5. Fitting with tachometric signal connection
The vehicle immobilisation is activated (with the engine on) at speed close to 0 Km/h. It is signalled by
the flashing of turn indicators (lasting about 3 hours).
THIS FUNCTION INCLUDES THE 7563 CONNECTION TO THE SENSOR GEMINI 7667.
6. Fitting without tachometric signal connection
The vehicle immobilisation is activated when the engine is shut off; It is not possible to start it again
without following the unlocking procedures described below. The immobilisation is signalled by the
flashing of turn indicators (lasting about 3 hours).
7. System unlocking with tag
To deactivate the system, the user must approach the vehicle with the TAG on. The module, receiving
a transmission again, deactivates the anti-hijack function and interrupts the flashing of turn indicators.
8. System unlocking with tag
This procedure is useful in case of an improper activation of the ant highjack function (e.g. failure or
TAG battery discharged with the anti-hijack function activated and vehicle running). The procedure to
deactivate the immobilisation function and allow the user to use the vehicle again is the following:
Press the status LED switch or insert the electronic key in the hole after at least 2 minutes
the anti-hijack warning has started. !
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Within 2 seconds after the LED switch has been pushed, press key 2 and then key 1 of the
system radio control.
NEW CONTROL DEVICE DETECTION
CAUTION
IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT
(DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS A
POSITIVE OUTCOME.
The alarm can store a maximum number of 12 control devices, such as radio controls, electronic keys,
TAG cards, magnetic contacts or infrared sensors (the latter not as control but as protection devices).
The procedure to carry out this operation is described below.
With the alarm deactivated, open and keep both the bonnet and the driver side door open.
THE " ON-OFF" OPERATIONS ARE CARRIED OUT WITHIN A MAXIMUM TIME OF FOUR SEC-
ONDS. IF THESE STEPS ARE NOT FOLLOWED, THE DATA STORAGE PROCEDURE OF NEW
DEVICES IS CANCELLED.
Turn the vehicle ignition key "ON".
Turn the vehicle ignition key "OFF".
Take the ignition key back to "ON" three times (ignition key "ON" and "OFF") and, as de-
scribed above, within a period of four seconds.
The fourth time the key is switched to "ON", leave the key in that position.
The alarm signals the start of the detection procedure of new control devices, magnetic
contacts or infrared sensors by means of two long turn indicator flashes and two sound
alarms, a high-pitched one and a grave tone one.
DO NOT CHANGE THE BONNET POSITION SINCE, INSTEAD OF STORING NEW DEVICES,
THOSE DEVICES PRESENT IN THE ALARM MEMORY ARE DELETED, AS DESCRIBED IN THE
FOLLOWING PARAGRAPH.
The alarm is now on hold, ready to receive the device code.
Press key No. 1 of the radio control, insert the electronic key in the appropriate hole, press
the TAG card key, activate the magnetic contact (bring contact and magnet together and
then separate them) or activate the infrared sensor (see instructions annexed to the sensor
section), according to the device to be stored.
In all the four cases, the alarm signals the detection of a new device by the flashing of the
status LED and a high-pitched tonality sound alarm.
Repeat the same operation to store other devices.
Turn indicators flash and the siren sounds with a grave tonality to signal the end of the
procedure.
TO STORE THE THIRTEENTH DEVICE, THE FIRST DEVICE ENTERED IN LOCATION ONE OF
THE ALARM MEMORY IS DELETED.
CONTROL DEVICE DELETION
CAUTION
ES - 145
IT IS NECESSARY THAT THE ELECTRICAL CONNECTIONS REQUIRED ARE CARRIED OUT
(DOOR SWITCH, BONNET SWITCH AND LIVE POSITIVE) SO THAT THE OPERATION HAS A
POSITIVE OUTCOME.
Control devices can be deleted from the alarm, such as radio controls, electronic keys, TAG cards,
magnetic contacts or infrared sensors (the latter as protection devices).
The procedure to carry out this operation is described below.
With the alarm deactivated, open and keep both the bonnet and the driver side door open.
CAUTION
THE " ON-OFF" OPERATIONS ARE CARRIED OUT WITHIN A MAXIMUM TIME OF FOUR SEC-
ONDS. IF THESE STEPS ARE NOT FOLLOWED, THE PROCEDURE TO DELETE DEVICES THAT
ARE IN THE MEMORY IS CANCELLED.
Turn the vehicle ignition key "ON".
Take the ignition key back to "ON" three times (ignition key "ON" and "OFF") and, as de-
scribed above within a period of four seconds.
The fourth time the ignition key is switched to "ON", leave it in that position.
The alarm signals the annulment of the control devices, magnetic contacts or infrared sen-
sors by means of two turn indicator flashes and two sound alarms, a high-pitched one and
a grave tone one.
Close the bonnet; the status LED remains steadily on
Leave the bonnet closed until, after about four seconds, the radio devices are completely
deleted.
IF THE VEHICLE BONNET IS CLOSED FOR LESS THAN FOUR SECONDS THE DELETION OF
RADIO DEVICES CAN NOT BE OBTAINED .
Deletion is signalled by the turning off of the status LED, a long flashing of turn indicators
and a sound alarm with grave tonality.
PROGRAMMED FUNCTIONS ARE NOT MODIFIED BY DELETING CONTROL DEVICES.
NEW PIN-CODE PROGRAMMING
Find below the procedure to personalise the PIN-CODE which, as previously described, is useful to
personalise the coded at the customer's will. In the example shown you want to enter a code with the
digits 5-4-6-7.
When the system is deactivated, open and keep the vehicle driver side door open.
Turn the ignition key to "ON".
The status LED turns on for 0.5 seconds. during that time, press both radio control keys at
the same time.
Following this operation, there are two sound alarms, a high-pitched one and a grave tone
one.
Close again the driver side door previously opened.
ES - 146
Press both keys of the radio control at the same time. The status LED turns off.
Turn the ignition key to "OFF".
The LED remains on for about 4 seconds to start the first series of flashes afterwards.
Once the LED has flashed for five times (corresponding to No. 5, first PIN-CODE digit), press
the status LED switch or turn the ignition key to "ON" for at least one second.
Take the vehicle ignition key back to "OFF".
The LED remains off for about 4 seconds to start a new series of flashes afterwards.
Once the LED has flashed four times (corresponding to No. 4, second PIN-CODE digit),
press the status LED switch or turn the ignition key to "ON" for at least one second.
Once the LED has flashed for six times (corresponding to No. 6, third PIN-CODE digit), press
the status LED switch or turn the ignition key to "ON" for at least one second.
Once the LED has flashed seven times (corresponding to No. 7, fourth and last PIN-CODE
digit), press the status LED switch or turn the ignition key to "ON" for at least one second.
Two sound alarms with grave tonality and one with high-pitch tonality signal that the proce-
dure has finished.
CAUTION
DURING THE PIN-CODE PROGRAMMING PHASE, IF THE NUMBER OF FLASHES EXCEED 9,
THAT PHASE IS CANCELLED AND THE ALARM STOPS THE PROCEDURE.
EMERGENCY UNLOCKING THROUGH PIN-CODE
The alarm emergency unlocking procedure through the PIN-CODE is described below. The original
PIN-CODE is set by Gemini, and consists of four digits 1-1-1-1. In the example shown, the alarm is
unlocked with the same digits shown in the CODE-PIN programming example ( 5-4-6-7).
To trigger an alarm status.
Let the alarm sound for a standard period (about 30 seconds) and wait for the "neutral period
between the two alarm warnings".
During this period the LED remains on for about 5 seconds; turn the vehicle ignition key to "ON".
DO NOT LET THE IGNITION KEY REMAIN IN " ON" FOR MORE THAN 3" OR THE SITUATION IS
INTERPRETED BY THE ALARM AS A THEFT ATTEMPT.
The LED turns off indicating that the "emergency unlocking procedure" has started.
Turn the vehicle ignition key to "OFF".
After about 4 seconds, the first sequence of 9 flashes has started.
ES - 147
Once the LED has flashed for five times (corresponding to No. 5, first PIN-CODE digit), turn
the ignition key to "ON" for at least one second (then turn it back to "OFF") or press the
status LED switch.
The LED remains off for about 4 seconds to start afterwards a new series of 9 flashes.
Once the LED has flashed for four times (corresponding to No. 4, second PIN-CODE digit),
turn the ignition key to "ON" for at least one second (then turn it back to "OFF") or press the
status LED switch.
Once the LED has flashed for six times (corresponding to No. 6, third PIN-CODE digit), turn
the ignition key to "ON" for at least one second (then turn it back to "OFF") or press the
status LED switch.
Once the LED has flashed for seven times (corresponding to No. 7, fourth PIN-CODE digit),
turn the ignition key to "ON" for at least one second (then turn it back to "OFF") or press the
status LED switch.
If the digits entered are exact, the unlocking procedure is signalled by the alarm and visual signalling/
sound alarms.
Vice versa, if digits entered are incorrect, a new alarm status is triggered.
In this case, repeat the procedure described above from the start.
DEVICE BATTERY REPLACEMENT
The use of different batteries from those recom-
mended could cause irreparable damage to the
remote control. Do not dispose of discharged bat-
teries in the environment, use the appropriate con-
tainers.
1 Magnetic contact
The intensity of the light given out by the LED in-
dicates the magnetic contact operation battery
charge status:
Intermittent or low intensity LED light,
battery discharged.
Permanent or high intensity LED light,
battery discharged.
To replace batteries, follow the instructions given
below:
With the alarm activated, open the
magnetic contact cover.
ES - 148
Take out exhausted batteries and re-
place them with new ones, paying at-
tention to observe polarity.
Refit the magnetic contact cover.
USE ONLY CR1616 TYPE BATTERIES
Open the TAG plastic using the crack located near
the slot by levering with a screwdriver. Take out
the circuit and slide off the discharged battery; fit
the charged battery holding the positive pole fac-
ing upwards. Refit the whole unit being careful that
it closes properly and effectively.
USE ONLY CR2032 TYPE BATTERIES FOR A LONGER
LIFE OF THE BATTERY TURN THE DEVICE OFF DURING
THE PERIODS OF INACTIVITY.
2. Radio control
To prevent remote control operation failures, the
latter has inside a device that indicates the battery
charge status. When using the radio control regu-
larly, press the control switch and the green warn-
ing LED turns on to remain steadily on. In case the
radio control battery charge status should de-
crease below the standard level in order to guar-
antee proper operation, by pressing the system
activation/deactivation switch, the green warning
LED turns on flashing, warning the user that it is
necessary a battery replacement.
USE ONLY CR1616 TYPE BATTERIES
3. Infrared sensor
When the battery voltage decreases below 5.5V, before reaching the minimum charge level for oper-
ation, the sensor signals such condition.
ES - 149
In fact, there is a visual signalling (LED) and a sound alarm (buzzer) which lasts one second following
each movement detection.
To replace the battery follow the instructions below:
Deactivate the alarm system.
Remove the sensor cover by slightly pressing on its upper and lower sides.
Remove the battery from its seat and separate it from the connector.
Replace the battery and close the cover removed previously again.
USE ONLY 9 VOLT TYPE BATTERIES.
Warranty conditions
Any manufacturing faults appearing on this appliance are guaranteed for a period of 24 months from
the installation date indicated in this guarantee slip, complying with directive 1999/44/EC with the im-
plementation of Legislative Decree No. 24 dated 02/02/2002.
Therefore, please fill in the entire warranty certificate included in this instruction manual and DO NOT
REMOVE the warranty label on the appliance.
The warranty is invalidated if such label or one of the parts are broken or missing while the certification
is filled in or the attached sales document is missing.
The warranty is exclusively valid at Gemini Technologies S.p.A. authorised centres
The manufacturer is not responsible for any faults or failures of the appliance or the vehicle electrical
system due to a bad installation, tampering or improper use.
The alarm has a theft deterrent function.
THE INSTALLATION CERTIFICATE AND THE RELEVANT PRODUCT WARRANTY IS AUTOMAT-
ICALLY INVALIDATED BY ANY TYPE OF MODIFICATION OR ADDITION NOT EXPRESSLY
INDICATED IN THE INSTALLER'S MANUAL, OR AUTHORISED BEFOREHAND BY GEMINI TECH-
NOLOGIES S.P.A.
Replacing light bulbs
LIGHT LAYOUT AND SPECIFICATIONS
1. Rear fog light
2. License plate light
3. Reverse light
4. Stop light and rear position
5. Rear hazard turn indicator
ES - 150
BULB POSITION AND CHARACTERISTICS
1. Headlamp and clearance lamp
2. Front and side hazard turn indicators/indicator
3. Fog light headlamp
CARATTERISTICHE DELLE LAMPADE
Faro 55 - 60 W
Lampeggiatori anteriore e laterale 21 W
Faro fendinebbia anteriore 55 W
Luce di ingombro 5 W
SPECIFICHE DELLE LUCI
Fari 60/55 W (Alogeno)
Luci di ingombro 5 W
Lampeggiatori anteriori 21 W
Lampeggiatori posteriori 21 W
Luce per retromarcia 21 W
Luci targa 5 W
Faro fendinebbia posteriore 21 W
Luce dell'abitacolo 5 W
Luce posteriore dell'abitacolo 5 W
Fari fendinebbia anteriori 55 W
Luce stop e posizione posteriore 21/5 W
ES - 151
Replacing the headlight bulbs
KEY:
1. Clip
2. Headlamp seat
3. Front turn indicators
4. Headlamp
Removal/Fitting
1. Remove the panel.
2. Undo and remove the fixing screw. Remove the
headlamp cover.
ES - 152
3. Remove the turn indicator locking spring.
4. Remove the turn indicator unit from the vehicle
inside.
5. Disconnect the connector and remove the turn
indicator.
6. Undo the two screws fixing the headlamp seat
to the front panel.
7. Remove the headlamp seat from the clip on the
front panel.
8. Undo the two screws fixing the headlamp to the
front panel.
9. Remove the headlamp from the clip located at
the bottom. To refit the headlamp unit, carry out
the same operations but in reverse order.
ES - 153
Replacing the front turn signal light bulbs
Front indicators
Removal/fitting
1. Remove the turn indicator 1 from its seat.
2. Disconnect the bulb holder.
3. Remove bulb 2 from bulb holder 3. To refit the
turn indicator, follow the same operations but in
reverse order.
Replacing the taillight bulbs
For Van and Combined models_
1. Undo the screw to remove the light unit.
2. Remove the bulb holder by turning it anticlock-
wise.
3. Remove the bulb by turning anticlockwise,
pressing it slightly.
ES - 154
Rear turn indicators/Stop lights
For the Pickup model
1. Take out the two screws to remove the light unit.
2. Turn the bulb anticlockwise by pressing it slight-
ly.
Replacing the license plate light bulb
License plate lights
1. Undo the two screws to remove the light unit.
2. Extract the bulb.
Replacing the courtesy lamp (passenger light)
Cab rear light
2. Take out the bulb by pulling it.
Cab lights
1. Remove the lenses by gently levering them.
2. Extract the bulb.
ES - 155
Fari fendinebbia
Fog light headlamps
Removal/fitting
1. Operating from the front compartment of the
bumper disconnect bulb holder 1 with the bulb and
remove it from the fog light headlamp support 2.
2. Remove bulb 3 from bulb holder 1.
To refit the fog light headlamp, carry out the same
operations but in reverse order.
Fog light headlamp replacement
1. Operating from the front compartment of the
bumper, disconnect connector 1 from bulb holder
2.
2. Undo the four fixing screws 3 of the fog light
headlamp 4 on support 5.
3. Remove the fog light headlamp 4 with the bulb
holder and bulb.
To refit the fog light headlamp, carry out the same
operations but in reverse order.
ES - 156
Luce retromarcia
Reverse gear light
1. Undo the screw to remove the light unit.
ly.
Faro fendinebbia posteriore
Rear fog light
ly.
Indicators - Warning lights
Gruppo strumenti
KEY:
1. Odometer
2 Warning light panel
3.Fuel gauge
4. Water temperature gauge
ES - 157
5. Speedometer
Components
INSTRUMENT PANEL
ES - 158
KEY:
1. Battery
2. F/L main fuse
3. F/C main fuse
4.Main switch
5. 20A Horn
6. Windscreen wiper
7.Hazard indicator switch
8. Turn indicator switch
9. Side light switch
10. Turn indicators
11.Left turn indicator light
12. Right turn indicator light
13. Hazard indicator
14.Lighting
15.To the ECU
16. 20A heater
17. Water temperature
18.Fuel gauge
19. Charge
20. Brake
ES - 159
21. Engine check bulb
22. Engine check bulb
23. Low fuel warning light
24. Beam
25. To the alternator (L)
26. 20A bulb
Fuel gauge
Check
Disconnect the fuel probe connector A placed at
the upper part of the fuel tank. Carry out the fol-
lowing checks on the receiving side end.
1. Disconnect the connector from the fuel level
probe cable harness. Earth the probe through a
check warning light.
2. Turn the ignition key switch to ON.
3. The check warning light turns on; after a few
seconds, the warning light must start flashing.
4. The fuel gauge must move up gradually.
KEY:
1. Battery
2. Link fuse
3. IG switch
4. Fuel gauge
5. Check warning light
6. Fuse
ES - 160
Fuel gauge
Unit check
1. Remove the combined instrument panel.
2. Measure the resistance value between termi-
nals B7 and B2.
3. Connect the multiple pole connector to the
"combination meter".
4.Turn the key switch to ON.
5. Make sure that battery voltage is applied be-
tween terminal A4 and the body ground.
6. Make sure that a variable voltage between 2 and
7 V is applied between terminal B7 and the body
ground.
Fuel level probe
Remove the fuel tank. Then, remove the fuel level probe.
Check
Measure the resistance value between the terminal and the body to the positions listed below.
Float A position: Resistance 5-10 Ohm Reference dimensions 95.5 3 mm
Float B position: Resistance 30-38 Ohm Reference dimensions 95.5 3 mm
Float C position: Resistance 87-102 Ohm Reference dimensions 230 3 mm
ES - 161
Fuel gauge and temperature gauge
KEY:
1. Battery
2. Fuel gauge
3. Gauge
5. Gauge
6. Fuel level probe
7. Water temperature probe
Water temperature gauge
1. Disconnect the connector from the water tem-
perature probe cable harness. Earth the gauge
through a check warning light.
Reference: about 55
2. Turn the key switch to ON.
3. The check warning light turns on. After a few
seconds, the warning light must start flashing.
4. The temperature gauge must start to move up
gradually.
KEY:
1. Link fuse
2. Battery
3. Fuse
4. Switch
6. Check warning light 3.4W
Water temperature probe
Check
ES - 162
1. Remove the probe from the cylinder head.
2. Measure the resistance value between the terminal and ground at the following temperatures:
Temperature (C) Resistance value ()
50 26.0
115 26.0
Controllo impianto di accensione
Ignition check
Spark plug
1. Connect the stroboscopic light terminal to the
ignition coil cable harness.
KEY:
A. Probe
B. Ignition coil
2. Check that the stroboscopic light flashes while
the engine in being run with the starter motor.
3.If it does not flash, carry out the following checks.
Remove the fuel pump relay from the relay hous-
ing.
4. Disconnect the ignition coil connector.
5. Remove the ignition coil and the spark plug.
6. Connect a spark plug and a connector to the
ignition coil.
- TESTER DS. 21. CAN BE USED
ES - 163
7. Check ignition sparks while the letting the en-
gine run with the starter motor.
8. Remove the spark plug.
- IF THERE ARE NO SPARKS, CHECK FOR POWER SUP-
PLY. - BEFORE CARRYING OUT THIS OPERATION,
CHECK FOR FUEL LEAKS INSIDE THE ENGINE COM-
PARTMENT. CLEAN THE FUEL LEAK, IF NECESSARY.
WORK IN A WELL VENTILATED AREA PAYING ATTEN-
TION THAT THERE ARE NO VOLATILE LIQUIDS, GAS,
ETC. NEARBY.
9. Spark plug cleaning.
N.B.
- REMOVE ANY OIL TRACES WITH PETROL BEFORE
CLEANING THE SPARK PLUG WITH THE APPROPRIATE
CLEANING DEVICE.
- IF THERE IS HUMID CARBON ON THE ELECTRODE, DRY
THE ELECTRODE AND CLEAN IT WITH THE APPROPRI-
ATE CLEANING DEVICE.
AIR PRESSURE:
IT MUST NOT EXCEED 588 KPA. DURATION: LESS THAN
20 SECONDS
10. Visually inspect the spark plug, checking that
the electrode is not worn and that the thread or
insulator is not damaged.
11. Check of distance between the electrodes.
Measure the distance between the electrodes with
a thickness gauge.
IF NECESSARY, REPLACE THE SPARK PLUG.
N.B.
- IF THE DISTANCE BETWEEN THE ELECTRODES DOES
NOT COMPLY TO THE SPECIFIED VALUES, ADJUST
BENDING THE EARTH ELECTRODE BASE PAYING AT-
TENTION NOT TO TOUCH THE FACE.
- THE FOUR SPARK PLUGS MUST BE AT THE SAME HEAT
RATING AND BELONGING TO THE SAME BRAND.
Characteristic
Electrode gap
0.9 - 1.0 mm
12. Checking spark plug insulation resistance to a
value higher than 20 M
- IF THE INSULATION RESISTANCE IS BELOW THE SPECI-
FIED VALUE, REPLACE THE SPARK PLUG.
ES - 164
13. Fit the spark plugs. Tighten to the prescribed
torque.
14. Fit the ignition coil on the cylinder head cover.
15. Connect the ignition coil connector.
Cylinder head - Spark plug 15 22 Cylinder head
cover - Ignition coil 611
Electrical power supply
2. Measure voltage between terminals 3 +B on the
wire connector side and with the ignition switch set
to ON.
- IF VOLTAGE DOES NOT COMPLY WITH THE SPECIFIED
VALUE, CHECK THE FUSE AND THE CABLE HARNESS.
Characteristic
Specified value:
Battery voltage
3. Connect the bulb (12 V/6 W) between terminals
S1 and GR on the wire connector side of the igni-
tion system. Check that the bulb turns on when the
engine is started with the starter motor.
N.B.
IN THESE CONDITIONS, THE BULB MUST START FLASH-
ING. OTHERWISE, CHECK THE SENSOR OUTPUT TERMI-
NAL OF THE CAMSHAFT SENSOR.
Ignition cable
2. Remove the ignition coil by taking out the fixing
nuts.
3. Disconnect the spacer and the cable from the
spark plug.
N.B.
- REMOVE THE IGNITION CABLE FROM THE SPARK
PLUGS AND FROM THE IGNITION COIL HOLDING THE
RUBBER SHEATH.
ES - 165
Camshaft sensor
1. Disconnect the camshaft sensor connector.
2. Measure the resistance between the connector
terminals.
Characteristic
Specified value:
230 25 ohm (a 20C)
3. Check that the waveform (see the signal shown
in the graphic) is shown on the oscilloscope dis-
play when the engine is started with the starter
motor.
- THE WAVEFORMS AS THOSE SHOWN IN THE FIGURE
ARE OBTAINED BY MEASURING THE VOLTAGE
THROUGH THE CONNECTOR TERMINALS DURING THE
ENGINE START-UP WITH AN APPROPRIATE OSCILLO-
SCOPE, IF THE SIGNAL GENERATOR WORKS PROPER-
LY.
4. Remove from the head, the camshaft sensor by
undoing the fixing bolt.
5. Remove the camshaft sensor cover.
6. Turn the rotor shaft until the signal rotor is facing
the signal generator.
7. In all the four points check that the air gap be-
tween the signal generator and signal rotor is
equal to the specified value.
- IF THE AIR GAP DOES NOT COMPLY WITH THE SPECI-
FICATIONS, ADJUST IT.
Characteristic
Specified air gap:
0.2 - 0.4 mm
8. Air gap adjustment.
Loosen the signal generator fixing
screws.
Adjust the air gap between the signal
generator and the signal rotor to the
prescribed value.
Tighten the signal generator fixing
screws.
ES - 166
9. Fit the camshaft sensor cover.
10. Fit the camshaft sensor on the head, and tight-
en the fixing bolt.
11. Check the ignition timing and adjust it if nec-
essary.
Accensione
Ignition timing
1. Set the ignition switch to OFF and connect the
following specific tool to the DLC A (Data Link
Connector) located at the lower part of the instru-
ment panel.
2. Connect a rpm indicator to the REV terminal,
using the following specific tool.
Specific tooling
020618Y Cable harness for connecting the
OBD Connector and the Diagnostic Tester
09991-87402-000 Rpm indicator pulse pickup
wire (Engine speed measurement)
3. Heat the engine.
4. Connect the stroboscopic light clamp to the ig-
nition coil of cylinder No.1 or No.4.
KEY:
A= Probe
B= Ignition coil
USE A STROBOSCOPIC LIGHT WITH INDUCTION
CLAMPS CALIBRATED AS PER THE HV COIL PRIMARY
SIGNAL.
ES - 167
5. J ump terminals T and E of the connector using
the following specific tool.
Specific tooling
Integrated in the 020618Y Lift for diagnosis
6. With a stroboscopic light, check that the ignition
timing reference on the flywheel matches the rear
plate reference.
- IGNITION TIMING SHOULD BE CHECKED OR ADJUSTED
USUALLY AFTER THE ENGINE IS FULLY HEATED.
Characteristic
Ignition timing:
Before Top Dead Centre 3 2/minimum
7. If the ignition timing reference is not aligned with
the indicator, adjust the ignition timing by turning
the camshaft sensor
- TURN THE CAMSHAFT SENSOR CLOCKWISE TO AD-
VANCE TIMING.
ECU - Centralina elettronica
Electronic injection control unit
1. Check if the diagnostic system indicates the fail-
ure codes.
ES - 168
2. Connection of the specific tool.
Disconnect the ground lead from the
battery negative (-) pole.
N.B.
- THE ELECTRONIC INJECTION UNIT CAN BE CHECKED
BY MEASURING THE RESISTANCE OR VOLTAGE ON THE
PROBES OF HE SPECIAL TOOL.
CAUTION
- BEFORE DISCONNECTING THE GROUND LEAD CHECK
IF THE FAILURE CODES ARE STORED. CUT OFF POWER
SUPPLY AND DATA STORAGE IS CANCELLED.
Disconnect the cable harness connec-
tor from electronic injection control unit
connectors on located on the upper
side of the glove-box.
Connect the specific tool between ca-
ble harness connectors and control
unit connectors.
Reconnect the ground lead from the
battery negative (-) pole.
CAUTION
- BEFORE DISCONNECTING OR RECONNECTING THE
ELECTRONIC INJECTION ECU CONNECTORS, DISCON-
NECT THE GROUND LEAD FROM THE BATTERY NEGA-
TIVE (-) POLE WITH THE IGNITION SWITCH AND ALL THE
ACCESSORY SWITCHES SET TO " OFF" .
- WHILE FITTING A NEW BATTERY, PAY ATTENTION NOT
TO INVERT POLARITY. AN INVERTED CONNECTION OF
POLES COULD DAMAGE THE CONTROL UNIT.
- BEFORE USING THE SPECIAL TOOL, CHECK WHETHER
ITS TERMINALS ARE SHORT CIRCUITED OR OPEN CIR-
CUIT.
3. Voltage or resistance measurement.
Measure the voltage or resistance be-
tween each terminal.
Check that the measured voltage or re-
sistance comply with specifications.
N.B.
- BESIDES, IF THE CHECK DESCRIBED ABOVE DETER-
MINES THAT THE CONTROL UNIT SHOULD BE RE-
PLACED, MAKE SURE THAT THE CONTROL UNIT FAIL-
URE IS NOT DUE TO EXTERNAL FACTORS. AFTER-
WARDS, REPLACE THE CONTROL UNIT.
- VOLTAGE MEASURED WITH ALL CONNECTORS CON-
NECTED.
Control unit output characteristics
Control unit voltage or resistance standard values are indicated in the table.
ES - 169
Unit Terminal Condition Standard voltage or
resistance
Solutions
Fuel supply 2 - 62 Always Battery voltage Check the fuse
11-62 43-62 Ignition switch set to "ON" Battery voltage Check the main relay
Earthing unit 20 52 62 Always Less or equal to 1 Check the cable har-
ness ground
Camshaft sen-
sor
21 -53 Run the engine with the starter
motor
0.1 - 0.3 V (AC scale) Check the camshaft
sensor and the cable
harness
Ignition coil
control
62-29 62-64 Ignition switch set to "ON" Less or equal to 3 V Check the control unit
Once the inspection has finished:
1. Disconnect the ground lead terminal to the battery negative (-) pole.
2. Remove the special tool, disconnecting the relevant connectors from the control unit and engine
cable harness connectors.
3. Connect the cable harness connectors to the control unit.
4. Reconnect the ground lead terminal to the battery negative (-) pole.
- IF THE VOLTAGE OR RESISTANCE MEASURED DOES NOT COMPLY WITH SPECIFICATIONS,
CHECK THE CABLE HARNESS.
- IF THE PROBLEM IS NOT SOLVED BY REPAIRING THE CABLE HARNESS OR THE COMPO-
NENTS, REPLACE THE ELECTRONIC INJECTION CONTROL UNIT.
Riscaldamento e ventilazione
Fan check
Fan check. Measure the resistance value between
following terminals.
Specified value:
1 - 3: ~2 Ohm
1 - 2: ~3 Ohm
Fan switch check
Make sure there is continuity between the respec-
tive terminals as indicated in the table.
ES - 170
Continuity table
A= Switch
B= Terminal
1= High
2= Average
3= Low
Main fitting operations
Temperature adjustment cable
Set the heater control temperature adjusting lever
to "COLD". Besides, set the lever on the heater
inlet pipe to "CLOSED". Insert the cable. Fit the
cable guide lock by inserting it in the bracket
grooves.
KEY:
A= Closed
B= Open
Internal/external air control cable
Set the heater control internal/external lever to In-
sert and lock the cable.
KEY:
C= Cold
D= Recirculation
ES - 171
Flow regulation cable
Take the heater control flow regulation lever to
"VENT". Insert and lock the cable.
E= VENT
Check after fitting
Make sure that the air quantity and flow direction match the control lever position
Operations after fitting
1. Fit the unit.
2. Supply the system.
3. Fit the battery negative (-) terminal.
4. Fit the front panel gasket (Van and Combined models).
Heating system and ventilation
COMPONENTS:
1. Defroster
2. Connector, etc.
3. Headlamp frame
4. Bumpers
5. Radiator
6. Cable for temperature check
7. Heater pipe
8. Heater unit
ES - 172
Removal
2. With the heating system adjustment lever set to
"hot", drain the water from the radiator (about 500
cm).
Radiator
Undo the fixing bolts. Take out the radiator down-
wards with the radiator pipes fitted on the radiator.
3. Remove the unit.
4. Remove the front panel gasket (Van and Com-
bined models).
ES - 173
Cooling Circuit
Cooling electric fan check
1. Turn the switch key to ON. Make sure that the
electric fan does not start turning when the liquid
temperature is below 92 C. Should this occur,
check the electric fan thermoswitch, and the cable
harness for possible short-circuits.
2. Disconnect the radiator thermoswitch connec-
tor.
3. Check that the radiator fan turns properly with
the ignition switch set to "ON" when the jumper is
connected to the connector terminals for the ther-
moswitch. If the fan does not turn, check the fan
motor assembly, fuse and remote control.
4. Connect the connector to the radiator thermos-
witch.
ES - 174
Installazione impianto elettrico
Engine injection cable harness
1. Engine ground
2. Oxygen sensor
3. Cam sensor
4. Water temperature sensor
5. Injector No. 4
6. Injector No. 3
7. Injector No. 2
8. Injector No. 1
9. Parking brake switch
10. Throttle position sensor
11.Pressure sensor
12.Air inlet temperature sensor
13. VSV 1 - fast idle
14.Oil pressure switch
15. EFI ECU (26 pin)
16 .To the instrument panel cable harness
17. Ignition coil
ES - 175
18. Ignition coil 2
From A
Position Terminal Terminal Position
Instrument panel cable har-
ness (Instrument panel, oil
pressure warning light)
H5 H6 Low oil pressure switch
Handbrake switch engaged
(+)
G7 G9 To the instrument panel cable
harness (Instrument panel,
handbrake warning light en-
gaged)
Connection to N5-N13 - N75 Ignition coil 2 (IG+)
Ignition coil 2 (-) N77 N56 EFI ECU (IG2)
Ignition coil 1 (IG +) N5 N31 To the instrument panel cable
harness (J /B fuse) B
Ignition coil 1 (-) N7 N27 EFI ECU(IG1)
Cam sensor (NE-) N47 N48 EFI ECU (N-)
Cam sensor (NE+) N8 N26 EFI ECU (N+)
EFI ECU(OX) X27 X28 Lambda probe (+)
EFI ECU (THW) X29 X30 Water temperature sensor (+)
Water temperature sensor (-) X31 - Connection to X35-X34
EFI ECU (THA) X32 X33 Intake air temperature sensor
(+)
EFI ECU (E2) X35 X34 Intake air temperature sensor
(-)
Connection to X38-X46 - X40 Throttle sensor (VC)
EFI ECU (VC) X38 X46 Pressure sensor (VC)
EFI ECU (PIM) X43 X45 Pressure sensor (PIM)
Connection to Z48-Z49 (near
X44)
- X44 Pressure sensor E1
Connection to X97-X100 - X50 Injector No. 1 (+)
EFI ECU (#10) X56 X51 Injector No. 1 (-)
Connection to X96-X98 - X53 Injector No. 2 (-)
Connection to X56-X51 - X55 Injector No. 3 (-)
EFI ECU (#20) X96 X98 Injector No. 4 (-)
ES - 176
From A
Injector No. 4 (+) X9 X100 To the instrument panel cable
harness (EFI (L) main relay)
EFI ECU (VSV1) X138 X254 (Fast idle) VSV1 (-)
EFI ECU (PSW) X203 X263 Accelerator sensor (PSW)
Connection to X97-X100 - X253 (Fast idle) VSV1 (+)
Connection to Z76-Z66 - Z221 Ignition coil 2 (E)
Connection to Z76-Z66 - Z220 Ignition coil 1 (E)
EFI ECU (E01) Z47 Z49 E/G ground
Connection to X35-X34 - Z140 Accelerator sensor (E2)
Connection to Z48-Z49 - Z212 Cam sensor
Connection to Z48-Z49 - Z213 Lambda probe sensor
Connection to Z76-Z66 - Z218 Ignition coil 2
Water temperature sensor H10 H20 To the instrument panel cable
harness and water tempera-
ture gauge
Connection to Z76-Z66 - Z216 Ignition coil 1
Connection to Z48-Z49 - Z190 Lambda probe sensor (-)
ES - 177
Battery negative cable harness (Pickup/Tipper)
1. Battery
2. Chassis
Cable harness unit
1. Engine cable harness
ES - 178
2. Instrument panel cable harness (Pick/Van/Tipper)
3. Van chassis cable harness
4. Courtesy light (roof) cable harness
5. Van roof light cable harness
6. Tail door cable harness No.1 (van)
7. Rear window cable harness No.1 (van)
8. Rear window cable harness No.2 (van)
Engine - chassis ground cable harness
1 Head cover
2. Chassis
ES - 179
Battery positive cable harness (Tipper)
1. Battery
2. To the vehicle cable harness
Battery positive cable harness (Pickup)
ES - 180
1. Battery
2. To the vehicle cable harness
Battery positive cable harness (Porter Van)
1 Battery
2 To the vehicle cable harness
ES - 181
Battery negative cable harness (Porter Van)
1 Battery
2 Chassis
Bodywork-engine ground transmission cable harness (Pickup)
ES - 182
1. Transmission (gear crankcase)
2. Body
Bodywork-engine ground transmission cable harness (van)
1. Transmission (gear crankcase)
2. Body
3. Foldable clamp
ES - 183
Cab roof cable harness (mirror courtesy light)
1. To the instrument panel cable harness
2. Internal lighting
POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEWS
From A
Light fuse (L) C2 C1 Courtesy light (+)
Courtesy light (DOOR) D1 D2 Courtesy light switch (+)
ES - 184
Roof light cable harness (Van)
1. To the chassis cable harness
2. Light fitting
POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEW
From A
Roof light D1 D2 Light switch (tail door) (+)
Light fuse (L) C3 C4 Roof light (+)
ES - 185
Tail door cable harness No.1 (Van)
1. To the chassis cable harness
2. Heated rear window defroster
From A
Light switch B1 B4 License plate light (+)
License plate light (+) B4 B5 License plate light (+)
Heated rear window defroster
switch
K1 K4 Heated rear window defroster
(+)
Chassis ground Z1 Z7 License plate light (-)
License plate light (-) Z7 Z8 License plate light (-)
ES - 186
Engine cable harness
1. Starter motor
2. Reverse gear light switch
3. To the battery positive cable harness
4. Alternator
5. To the instrument panel cable harness (fuses)
6. To the instrument panel cable harness
POSITIONS OF CABLES IN THE CONNECTORS - CONNECTOR FRONT SIDE VIEW
From A
F/L EFI fuse M10 X4 EFI fuse
F/L Main fuse X2 N1 Main fuse
J /B Fuse box (ignition switch/B) 022 018 Alternator (B)
Ignition switch (ST) M1 M2 Starter motor (ST)
Bulb switch
reverse gear (-)
G3 G1 Reverse gear bulb
(+)
J /B-Fuse box (Heating fuse) G4 G2 Reverse gear bulb
switch (+)
J /B-Fuse box (Engine fuse) 021 019 Alternator (IG)
Instrument panel (charge bulb) 023 020 Alternator (L)
ES - 187
Rear chassis cable harness (Porter Van)
1.Rear left lights
2.To the tail door (rear window wiper)
3. To the roof (roof light)
4. Rear left fog light
5.To the instrument panel cable harness
6. Chassis earthing
7. Reverse gear light
8.Rear right fog light
9.To the tail door cable harness (license plate and heated rear window)
10.Tail door courtesy light switch
11.Rear right lights
From A
Rear right fog light (+) B6 B7 Rear fog light switch (L)
Light switch B5 B4 License plate light (+)
Light switch B18 B3 Right position light
Connection to B6-B7 - B8 Rear left fog light (+)
Connection to B18-B3 - B2 Left position light
Light fuse (L) C3 C4 Roof light (+B)
Stop light switch E1 E5 Right stop light
ES - 188
From A
Connection to E1-E5 - E6 Left stop light
Right turn indicator light switch F1 F7 Rear right turn indicator light
Left turn indicator light switch F2 F9 Rear left turn indicator light
Roof light (L) D1 D2 Tail door courtesy light switch
(+)
Reverse gear light switch G1 G7 Reverse gear light (+)
Chassis ground Z1 Z8 Chassis ground (J /B(-) Con-
nection box)
Connection to Z1-Z8 - Z4 Rear right lights (E)
Connection to Z1-Z8 - Z5 Rear left lights (E)
Connection to Z1-Z8 - Z3 Tail door courtesy light switch
(-)
Defroster switch K1 K4 Heated rear window
Rear window wiper (L) I1 I14 Rear window wiper (+)
Rear window wiper switch I12 I13 Rear window wiper (-)
Connection to Z1-Z8 - Z6 Reverse gear light (-)
Connection to Z1-Z8 - Z7 License plate light (-)
Connection to Z1-Z8 - Z9 Rear left fog light (-)
Connection to Z1-Z8 - Z10 Rear right fog light (-)
ES - 189
Cruscotto
INSTRUMENT PANEL CABLES
RIGHT HAND DRIVE INSTRUMENT PANEL:
1 Diode
2 To the injection cable harness
3 EFI fuses No. 1 - No. 2
4 EFI ECU
5 Diode
6 To the courtesy light cable harness
7 Diagnostic check
8 Front left chassis ground
9 Front left position light
10 radiator cooling electric fan motor
11 Left headlight
12 Left headlight adjustment actuator
13 Horn
14 Left fog light
15 windshield washer motor
16 Front left /side turn indicator
ES - 190
17 coolant temperature sensor
18 radiator fan relay
19 main fuse
20 to the engine cable harness
21 to the engine cable harness
22 J /B C connection
23 Fog light fuse
24 J /B A connection
25 electric heater motor
26 stop light switch
27 loudspeaker
28 windscreen wiper motor
29 key switch
30 headlight adjustment switch
31 heating resistance component
32 flashing light switch
33 fog light relay
34 J /B B connection
35 Headlight fuses
36 instrument panel
37 electric heater fan switch
38 radio
39 cigarette lighter
40 fuel pump
41 fuel and low fuel gauge
42 chassis ground
43 rear fog light
44 rear right light
45 reverse gear light
46 left license plate light
47 right license plate light
48 rear left light
49 front right /side turn indicator
50 right fog light
51 right headlight adjustment actuator
52 right headlight
53 front right position light
54 front right chassis ground
ES - 191
55 fog light switch
56 rear fog light switch
57 main relay box and fuel pump
58 brake fluid level switch
59 courtesy light switch
Da A
Posizione Terminale Terminale Posizione
Proiettore destro (HI) A1 A2 Proiettore sinistro (HI)
Proiettore destro (LO) A3 A4 Proiettore sinistro (LO)
Collegamento a A1-A2 A5 Commutatore lampeggiatori
(Commutazione (HU))
Collegamento a A3-A4 A6 Commutatore lampeggiatori
(Commutazione (HL))
Collegamento a A1-A2 A7 Quadro strumenti (Spia abba-
glianti)
Fusibile proiettore sinistro (B) A21 A8 J /B C - Scatola fusibili (Fusibile
luci: L)
Proiettore destro (+B) A9 A24 Fusibile proiettore destro (B)
Collegamento a A22-A14 A10 Quadro strumenti (Spia abba-
glianti (+))
Proiettore sinistro (+B) A11 A23 Fusibile proiettore sinistro (L)
Collegamento a A22-A14 A12 Luce di cortesia (B)
Fusibile proiettore destro (B) A22 A14 J /B C - Scatola fusibili (Fusibile
luci: L)
Collegamento a A3-A4 A15 Diodo (uscita)
Collegamento a A1 -A2 A16 Diodo (uscita)
Interruttore luci ind. direzione
(emergenza)
A19 A39 Quadro strumenti (Spia emer-
genza)
Collegamento a A9-A24 A54 Orientamento proiettore des-
tro (+)
Collegamento a A11-A23 A61 Orientamento proiettore sinis-
tro (+)
Orientamento proiettore des-
tro (0)
A56 A63 Orientamento proiettore sinis-
tro (0)
Collegamento a A56-A63 A69 Resistenza (R4)
ES - 192
Da A
Collegamento a A11 -A23 A70 Resistenza (R3)
Resistenza (R4) A71 A75 Interruttore orientamento
proiettori
proiettori
proiettori
Luce posizione anteriore (des-
tra)
B1 B2 Luce posizione anteriore (sin-
istra)
Collegamento a B1-B2 B3 Luce posizione posteriore
destra (B)
Collegamento a ~B3 B4 Luce posizione posteriore sin-
istra (B)
Collegamento a B1-B2 B5 Commutatore lampeggiatori
(Illuminazione (-))
Interruttore retronebbia (L) B7 B15 Luci retronebbia (+)
Interruttore fendinebbia B21 B16 Rel luci fendinebbia
Fusibile (fendinebbia) B17 B18 Rel luci fendinebbia
Collegamento a B1-B2 B20 Interruttore luci fendinebbia
Rel fendinebbia B19 B22 Luce fendinebbia destro
Collegamento a B21-B22 B23 Luce fendinebbia sinistra
Interruttore lampeggiatori
(Fendinebbia)
C1 C20 Interruttore retronebbia (B)
Collegamento a B1-B2 C2 Quadro strumenti (illumina-
zione)
Collegamento a B1-B2 C3 Luce targa destra (B)
Collegamento a B1-B2 C4 Interruttore riscaldatore (Illu-
minazione)
Collegamento a C3 C7 Luce targa sinistra (+)
Luce di cortesia (-) D1 D2 Interruttore luce di cortesia (+)
Fusibile clacson J /B C (L) -
Scatola fusibili
E1 E7 Interruttore luci stop (+)
Clacson (+) E2 E7 Interruttore luci stop (+)
Clacson (-) E3 E4 Interruttore lampeggiatori
(Clacson (+))
ES - 193
Da A
Fanale luci posteriori (Luce
stop destra (+))
E5 E6 Interrutore luci stop (-)
Fanale luci posteriori (Luce
stop destra (+))
E5 E8 Fanale luci posteriori (Luce
stop sinistro)
Commutatore lampeggiatori
(destri)
F1 F9 Lampeggiatore anteriore/lat-
erale destro
(sinistri)
F3 F10 Lampeggiatore anteriore/lat-
erale sinistro
Collegamento a F1-F9 F5 Quadro strumenti (spia lamp-
eggiatori)
Collegamento a F3-F10 F6 Quadro strumenti (spia lamp-
eggiatori)
Collegamento a F1-F9 F7 Lampeggiatore posteriore
destro
Collegamento a F3-F10 F8 Lampeggiatore posteriore sin-
istro
Interruttore freno a mano G1 G5 Quadro strumenti (Spia freno
a mano)
Quadro strumenti (Spia livello
olio freni)
G2 G3 Interruttore insufficiente livello
olio freni
Interruttore luce retromarcia
(-)
G6 G7 Luce retromarcia (+)
Trasmettitore livello carbur-
ante (+)
H2 H3 Quadro strumenti (Indicatore
livello carburante)
Interruttore pressione olio (+) H4 H5 Quadro strumenti (Spia press-
ione olio)
Quadro strumenti (Indicatore
temperatura liquido refriger-
ante)
H6 H7 Sensore temperatura liquido
refrigerante (+)
Quadro strumenti (Spia riser-
va carburante)
H8 H9 Sensore livello carburante (ris-
erva)
J /B C (Fusibile tergicristallo) I1 I2 Motorino Tergicristallo (+)
(Tergicristallo (+1))
I3 I4 Motorino Tergicristallo (+1)
Motorino lavacristallo (-) I5 I6 Commutatore lampeggiatori
(Lavacristallo)
ES - 194
Da A
(Tergicristallo (+2))
I7 I8 Motorino Tergicristallo (+2)
Collegamento a 11-12 I9 Motorino Lavacristallo (+)
J /B C (Rel tergicristallo lnt.:S) I16 I17 Motorino Tergicristallo (S)
Collegamento a K5-K6 Collegamento a K36-K14
J /B C (Fusibile riscaldatore
(L))
K5 K6 Motorino riscaldamento (+)
Interruttore ventola riscalda-
mento (HI)
K7 K8 Motorino riscaldamento (-)
Motore ventola riscaldamento
(-)
K8 K9 Resistenza riscaldamento (HI)
mento (ME)
K10 K11 Resistenza riscaldamento
(ME)
mento (LO)
K12 K13 Resistenza riscaldamento
(LO)
J /B C (Fusibile riscaldamento
(L))
K36 K14 Interruttore riscaldamento (B)
Collegamento a K5-K6 K17 Interruttore luce retromarcia
(+)
Collegamento a K5-K6 K18 Quadro strumenti (+B)
Collegamento a K12-K13 KA1 Diodo (uscita)
Rel motore radiatore L26 L1 Motore ventola radiatore (+)
Collegamento a B19-B22 B24 Diodo (entrata) (interruttore
retronebbia)
Collegamento a A22-A14 B25 Diodo (uscita) (interruttore ret-
ronebbia)
Rel ventola radiatore (L) L17 L21 Sensore temperatura liquido
refrigerante (LO)
Collegamento a L2-L16 L11 Alternatore (IG)
Fuse engine 20A L2 L16 Rel ventola radiatore (B)
Collegamento a Z32-Z8 L10 Motore ventola radiatore
Collegamento a N1 ~N2 L25 Rel ventola radiatore (+)
Collegamento a Z32-Z8 L22 Termo sensore ventola radia-
tore (-)
Collegamento a L33-L40 L31 Iniettore n 4 (+)
ES - 195
Da A
R/B (Rel principale (L)) L33 L40 R/B (Rel pompa carburante
(+B))
R/B (Rel principale (+S)) L42 L39 R/B (Rel pompa carburante
(+S))
Fusibile EFI n 1 L41A L41 R/B (Rel principale (+B))
Fusibile EFI n 2 L48 L42 R/B (Rel principale (+S))
Collegamento a L17 ~L21 L46 EFI ECU (A/T)
Collegamento a-X152 L50 Diodo (IN)
Fusible principale (B) M1 M2 Principale F/L
Commutatore chiave (ST) M3 M4 Motorino d'avviamento (ST)
Fusibile principale (L) N1 N2 J /B A (Commutatore a chiave
B))
Collegamento a N1-N2 N3 Commutatore a chiave (B)
Commutatore chiave (IG) N7 N15 J /B A (Commutatore a chiave
IG)
Collegamento a L2-L16 N8 Accensione
Collegamento a N7-N15 N16 J /B A (Commutatore a chiave
(IG1 ))
EFI F/L N35 N46 Fusibile EFI 1
Commutatore a chiave (IG2) N30 N37 Fusibile EFI n 2
Collegamento a L48-L42 N38 Controllo diagnostico (IG2)
Collegamento a N1-N2 N39 Fusibile (Fendinebbia)
Collegamento a N1-N2 01 Alternatore (B)
Quadro strumenti (Spia carica
batteria)
03 04 Alternatore (L)
J /B C (Fusibile ACC(L)) R1 R2 Accendisigari (+)
Collegamento a R1-R2 R4 Autoradio (+)
Commutatore a chiave (ACC) R6 R7 J /B A (Commutatore a chiave
(ACC))
Autoradio (Altoparlante (+)) R13 R15 Altoparlante (+)
Autoradio (Altoparlante (-)) R14 R16 Altoparlante (-)
R/B (Rel pompa carburante
(L))
U7 U12 Pompa carburante (+B)
EFI ECU diagnostica (W) X2 T4 Quadro strumenti (Diagnosti-
ca)
ES - 196
Da A
EFI ECU velocit (SPD) X4 H38 Quadro strumenti (Tachimetro
sensore velocit)
R/B (Rel pompa carburante (-
S))
X8 X257 EFI ECU (FC)
Controllo diagnostico (VF) X20 X21 EFI ECU (VF)
Collegamento a L41A-L41 X23 EFI ECU (BAT)
EFI ECU (DSW2) X18 X152 Diodo (IN)
Collegamento a K12-K13 X219 EFI ECU (BLW)
Collegamento a L33-L40 X251 EFIECU(+B1)
Collegamento a L33-L40 X252 EFIECU(+B2)
Controllo diagnostico (T) X57 X266 EFI ECU (T)
EFI ECU (SIO) X268 X269 Controllo diagnostico (SIO)
EFI ECU (REV) X242 X271 Controllo diagnostico (REV)
Massa telaio anteriore destra Z1 Z2 Massa telaio anteriore sinistro
Collegamento a Z1-Z2 Z3 Quadro strumenti (Massa)
Collegamento a Z1-Z2 Z4 Interruttore luce cortesia (-)
Collegamento a Z32-Z8 Z5 Massa telalo posteriore
Collegamento a Z1-Z2 Z7 Interruttore ventola riscalda-
mento (-)
Massa telaio anteriore destra Z32 Z8 J /B B (Massa)
Collegamento a Z1 -Z2 Z10 Lampeggiatore anteriore/lat-
erale destro (-)
Collegamento a Z32-Z8 Z11 Lampeggiatore anteriore/lat-
erale sinistro (-)
Collegamento a Z1-Z2 Z13 Interruttore insufficiente livello
olio freni (-)
Collegamento a Z32-Z8 Z17 Luce posizione anteriore sin-
istra (-)
Collegamento a Z1 -Z2 Z18 Luce posizione anteriore des-
tra (-)
Collegamento a Z1-Z2 Z19 Interruttore fendinebbia
Collegamento a Z1 -Z2 Z20 Fendinebbia destro
Collegamento a Z1-Z2 Z21 Fendinebbia sinistro
Collegamento a Z1-Z2 Z22 Rel fendinebbia
Collegamento a -Z5 Z23 Fanale luci posteriori sinistro
Collegamento a Z1-Z2 Z26 Accendisigari (-)
ES - 197
Da A
Massa telaio anteriore sinistra Z12 Z27 Autoradio (-)
Collegamento a -Z5 Z33 Luce targa destra (-)
Collegamento a -Z5 Z34 Luce retromarcia
Collegamento a -Z5 Z37 Luce targa sinistra (-)
Collegamento a Z1 -Z2 Z84 Pompa carburante (Massa)
Collegamento a Z1-Z2 Z85 R/B (Rel principale (-S))
Collegamento a Z1 -Z2 ZA5 Interruttore retronebbia (-)
Collegamento a -Z5 ZA8 Luce retronebbia
Collegamento a Z1 -Z2 ZB1 Attuatore regolazione proiet-
tore destro (-)
Collegamento a Z1-Z2 ZB2 Attuatore regolazione proiet-
tore sinistro (-)
Collegamento a ZB1-ZB2 ZB3 Resistenza (R1)
Resistenza (R1) ZB4 ZB5 Interruttore orientamento
proiettori
Resistenza (R1) ZB4 ZC3 Interruttore orientamento
proiettori
Collegamento a Z1 -Z2 ZB7 Tergicristallo (-)
Collegamento a Z1 -Z2 ZC1 Quadro strumenti
Collegamento a Z1-Z2 ZC2 Quadro strumenti
Collegamento a Z1-Z2 ZC4 EFI ECU ventola radiatore
Collegamento a -Z5 Z35 Fanale luci posteriori destro (-)
ES - 198
LEFT HAND DRIVE INSTRUMENT PANEL:
1. Main relay locking and fuel pump relay
2. Brake fluid level switch
3. Courtesy light switch
4. Buzzer
5. Left headlight adjustment actuator
6. Front left chassis ground
7. Front left position light
8. Left headlight
9. Horn
10. Left fog light
11. Front left/side turn indicator
12. Headlight adjustment switch
13. Rear fog light switch
14. Fog light switch
15. Loudspeaker
16. Stop light switch
17. J /B A connection
18. Fog light fuse
ES - 199
20. Flashing light switch
21. J /B B connection
22. Headlight fuses
23. Fog light relay
24. Windshield washer motor
25. Coolant temperature sensor
26. Radiator electric fan relay
27. Main fuse
28 . to the engine cable harness
30. Fuel pump
31. Fuel and low fuel gauge
32. Chassis earthing
33. Rear left lights
34. Rear fog light
37. Rear right lights
38. Diode
39. Diode
40. Radiator cooling electric fan
41. To the injection cable harness
43. 12V Acc. socket / Cigarette lighter
44. Radio
45. Radio
46. Front right /side turn indicator
47. Electric heater fan switch
48. Right fog light
49. Right headlight
50. Right headlight adjustment actuator
51. Front right position light
52. Front right chassis ground
53. To the courtesy light cable harness
54. Electric fan motor
55. Heater resistance
56. EFI fuse No. 1 - EFI fuse No. 2
ES - 200
57. Diagnostic check
58. Windscreen wiper motor
60. Instrument panel
61. Key switch
ble class=editor height="60%" width="70%" border=1>
From A
Right headlight (HI) A1 A2 Left headlight (HI)
Right headlight (LO) A3 A4 Left headlight (LO)
Connection to A1-A2 A5 Turn indicator switch (Switch-
ing (HU))
ing (HL))
Connection to A1-A2 A7 Instrument panel (High beam
warning light)
Left headlight fuse (B) A21 A8 J /B C (Light fuse: L)
Right headlight (+B) A9 A24 Right headlight fuse (B)
warning light)
Left headlight (+B) A11 A23 Left headlight fuse (L)
Connection to A22-A14 A12 Courtesy light (B)
Right headlamp (B) A22 A14 J /B C (Light fuse: L)
Connection to A3-A4 A15 Diode (output)
Turn indicator switch (emer-
gency)
A19 A39 Instrument panel (emergency
warning light)
Connection to A9-A24 A54 Right headlight aiming (+)
Connection to A11 -A23 A61 Left headlight aiming (0)
Right headlamp aiming (0) A56 A63 Left headlight aiming (0)
Connection to A56-A63 A69 Resistance (R4)
Connection to A11 -A23 A70 Resistance (R3)
Resistance (R4) A71 A75 Headlight aiming switch
ES - 201
From A
Front position light (right) B1 B2 Front position light (left)
Connection to B1-B2 B3 Rear right position light (B)
Connection to B18-B3 B4 Rear left position light (B)
Connection to B1-B2 B5 Turn indicator switch (lighting
(-))
Rear fog light switch (L) B7 B15 Rear fog light (+)
Fog light switch B21 B16 Fog light relay
Fuse (fog light) B17 B18 Fog light relay
Connection to B1-B2 B20 Rear fog light switch
Fog light relay B19 B22 Right fog light
Connection to B22-B19 B23 Left fog light
Turn indicator switch (Fog
lights)
C1 C20 Rear fog light switch (B)
Connection to B1-B2 C2 Instrument panel (lighting)
Connection to B1-B2 C3 Right license plate light (B)
Connection to B1-B2 C4 Heater switch (lighting)
Connection to -C3 C7 Left license plate light (+)
Courtesy light (-) D1 D2 Courtesy light switch (+)
J /B C horn fuse (L) E1 E7 Stop light switch (+)
Horn (+) E2 E7 Stop light switch (+)
Horn (-) E3 E4 Turn indicator switch (Horn
(+))
Rear lights (Right stop light
(+))
E5 E6 Stop light switch (-)
(+))
E5 E8 Rear lights. (Left stop light)
Right turn indicator switch F1 F9 Front right /side turn indicator
Left turn indicator switch F3 F10 Front left /side turn indicator
Connection to F1-F9 F5 Instrument panel (turn indica-
tor warning light)
Connection to F3-F10 F6 Instrument panel (turn indica-
tor warning light)
Connection to F1-F9 F7 Rear right turn indicator
Connection to F3-F10 F8 Rear left turn indicator
Handbrake switch G1 G5 Instrument panel (handbrake
warning light)
ES - 202
From A
Instrument panel (brake oil
level warning lights)
G2 G3 Low brake oil level switch
Reverse gear light switch (-) G6 G7 Reverse gear light (+)
Fuel level transmitter (+) H2 H3 Instrument panel (fuel gauge)
Oil pressure switch (+) H4 H5 Instrument panel (oil pressure
warning light)
Instrument panel (Coolant
temp. gauge)
H6 H7 Coolant temperature sensor
(+)
Instrument panel (Low fuel
warning light)
H8 H9 Fuel level sensor (reserve)
Connection to B1-B2 H50 Sounding mechanism (lights
on)
Sounding mechanism (lights
on)
H51 H52 Diode (input)
Diode (output) H53 D2 Courtesy light switch (+)
Connection to B19-B22 B24 Diode (input) (Rear fog light
switch)
Connection to A22-A14 B25 Diode (output) (Rear fog light
switch)
J /B A (Windscreen wiper fuse) I1 I2 Windscreen wiper motor (+)
Turn indicator switch (Wind-
screen wiper (+1))
I3 I4 Windscreen wiper motor (+1)
Windshield washer motor (-) I5 I6 Turn indicator switch (Wind-
shield washer)
screen wiper (+2))
Connection to I1-I2 I9 Windshield washer motor (+)
J /B A (Int. windscreen wiper
relay: S)
I16 I17 Windscreen wiper (S)
Connection to K5-K6 Connection to K36-K14
J /B A (Heater fuse (L)) K5 K6 Heating motor (+)
Heating fan switch (HI) K7 K8 Heating motor (-)
Heating fan motor (-) K8 K9 Heating resistance (HI)
Heating fan switch (ME) K10 K11 Heating resistance (ME)
Heating fan switch (LO) K12 K13 Heating resistance (LO)
J /B A (Heater fuse (L)) K36 K14 Heating switch (B)
ES - 203
From A
Connection to K5-K6 K17 Reverse gear light switch (+)
Connection to K5-K6 K18 Instrument panel (+B)
Connection to K12-K13 KA1 Diode (output)
Radiator motor relay L26 L1 Radiator fan motor (+)
Radiator fan relay (-) L17 L21 Coolant temperature sensor
(LO)
Connection to L2-L16 L11 Alternator (IG)
FUSE ENGINE 20A L2 L16 Radiator fan relay (B)
Connection to Z32-Z8 L10 Radiator fan motor
Connection to N1-N2 L25 Radiator fan relay (+)
Connection to Z32-Z8 L22 Radiator fan thermal sensor
Connection to L33-L40 L31 Injector No. 4 (+)
R/B (Main relay (L)) L33 L40 R/B (Fuel pump relay (+B))
R/B (Main relay (+S)) L42 L39 R/B (Fuel pump relay (+S))
EFI fuse No. 1 L41A L41 R/B (Main relay (+B))
EFI fuse No. 2 L48 L42 R/B (Main relay (+S))
Connection to L17-L21 L46 EFI ECU (A/T)
Connection to X152 L50 Diode (IN)
Main fuse (B) M1 M2 F/L Main fuse
Key switch (ST) M3 M4 Starter motor (ST)
Main fuse (L) N1 N2 J /B A (Key switch (B))
Connection to N1-N2 N3 Key switch (B)
Key switch (IG) N7 N15 J /B A (Key switch IG)
Connection to L2-L16 N8 Ignition
Connection to N7-N15 N16 J /B A (Key switch (IG1 ))
EFI F/L N35 N46 EFI fuse No. 1
Key switch (IG2) N30 N37 EFI fuse No. 2
Connection to L48-L42 N38 Diagnosis check (IG2)
Connection to N1-N2 O1 Alternator (B)
Instrument panel (Battery
charge warning light)
O3 O4 Alternator (L)
J /B B (ACC fuse (L)) R1 R2 Cigarette lighter (+)
Connection to R1-R2 R4 Car radio (+)
Key switch (ACC) R6 R7 J /B A (Key switch (ACC))
Car radio (Loudspeaker (+)) R13 R15 Loudspeaker (+)
Car radio (Loudspeaker (-)) R14 R16 Loudspeaker (-)
ES - 204
From A
R/B (Fuel pump relay (L)) U7 U12 Fuel pump (+B)
EFI ECU - diagnosis (W) X2 T4 Diagnosis instrument panel
(Diagnosis)
EFI ECU - speed (SPD) X4 H38 Speed sensor instrument pan-
el (Speedometer)
R/B (Fuel pump relay (-S)) X8 X257 EFI ECU (FC)
Instrument panel (VF) X20 X21 EFI ECU (VF)
Connection to L41A-L41 X23 EFI ECU (BAT)
EFI ECU (DSW2) X18 X152 Diode (IN)
Connection to K12-K13 X219 EFI ECU (BLW)
Connection to L33-L40 X251 EFI ECU (+B1)
Diagnostic check (T) X57 X266 EFI ECU (T)
EFI ECU (SIO) X268 X269 Diagnostic check (SIO)
EFI ECU (REV) X242 X271 Diagnostic check (REV)
Front right chassis ground Z1 Z2 Front left chassis ground
Connection to Z1 -Z2 Z3 Instrument panel (Ground)
Connection to Z1 -Z2 Z4 Courtesy light switch (-)
Connection to Z32-Z8 Z5 Rear chassis ground
Connection to Z1 -Z2 Z7 Heating fan switch (-)
Front right chassis ground Z32 Z8 J /B B (Ground)
Connection to Z1 -Z2 Z10 Front right side turn indicator
(-)
Connection to Z32-Z8 Z11 Front left side turn indicator (-)
Connection to Z1 -Z2 Z13 Low brake oil level switch (-)
Connection to Z32-Z8 Z17 Front left position light (-)
Connection to Z1 -Z2 Z18 Front right position light (-)
Connection to Z1 -Z2 Z19 Fog light switch
Connection to Z1 -Z2 Z20 Right fog light
Connection to Z1 -Z2 Z21 Left fog light
Connection to Z1 -Z2 Z22 Fog light relay
Connection to -Z5 Z23 Rear left lights
Connection to -Z5 Z35 Rear right lights
Connection to Z1 -Z2 Z26 Cigarette lighter (-)
Front left chassis ground Z12 Z27 Car radio (-)
Connection to -Z5 Z33 Right license plate light (-)
ES - 205
From A
Connection to -Z5 Z34 Reverse gear light
Connection to -Z5 Z37 Left license plate light (-)
Connection to Z1 -Z2 Z84 Fuel pump (Ground)
Connection to Z1 -72 Z85 R/B (Main relay (-S))
Connection to Z1 -Z2 ZA5 Rear fog light switch (-)
Connection to -Z5 ZA8 Rear fog light (-)
Connection to Z1 -Z2 ZB1 Right headlight adjustment ac-
tuator (-)
Connection to Z1 -Z2 ZB2 Left headlight adjustment ac-
tuator
Connection to Z1 -Z2 ZB4 ZB3 Resistance (R1)
Resistance (R1) ZB4 ZB5 Headlight aiming switch
Resistance (R1) ZC3 Headlight aiming switch
Connection to Z1 -Z2 ZB7 Windscreen wiper motor (-)
Connection to Z1 -Z2 ZC1 Diagnostic check
Connection to Z1 -Z2 ZC4 EFI ECU - fan
Connection to N1-N2 N39 Fog light fuse
Cablaggio cruscotto (Furgone-guida a destra)
ES - 206
RIGHT HAND DRIVE VAN:
2. left headlight adjustment actuator
3. front left /side turn indicator
4. front left fog light
5. left headlight
7. Diode
8. Diode
10. EFI ECU
13. radiator cooling electric fan
14. windshield washer motor
15. rear window washer motor
16. temperature sensor
17. radiator fan relay
18. main fuse
ES - 207
19. to the engine cable harness
20. to the engine cable harness
21. to the chassis cable harness
22. fuel pump
23. fuel and low fuel gauge
24. stop light switch
25. electric heater motor
27. Fog light fuse
28. J /B C connection
29. front fog light relay
30. headlight fuses
32. flashing light switch
33. key switch
34. loudspeaker
35. cigarette lighter
36. radio
37. Electric heater fan switch
38. heating resistance component
39. headlight adjustment switch
40. windscreen wiper motor
41. instrument panel
42. right headlight adjustment actuator
43. front right fog light
44. front right /side turn indicator
45. right headlight
46. front right position light
47. front right chassis ground
48. courtesy light switch
49. brake fluid level switch
50. main relay box and fuel pump
51. rear defroster switch
52.rear window wiper switch
53. rear fog light switch
54. fog light switch
ES - 208
From A
ing (HU)
ing (HL)
warning light)
Left headlight fuse (B) A21 A8 J /B C Fuse box (Light fuse: L)
Right headlight (+B) A9 A24 Right headlight fuse (B)
warning light+)
Left headlight (+B) A11 A23 Left headlight fuse (L)
Connection to A22-A14 A13 Ceiling light (B)
Right headlight fuse (B) A22 A14 J /B C Fuse box (Light fuse: L)
Turn ind. switch (emergency) A19 A39 Instrument panel (Emergency
warning light)
Connection to A11 -A23 A61 Left headlight aiming (+)
Right headlight aiming (0) A56 A63 Left headlight aiming (0)
(-))
fog light switch B21 B16 Fog light relay
ES - 209
From A
Turn indicator switch (fog
lights)
Connection to B1-B2 C4 Heater switch (Lighting)
J /B C horn fuse (L) - Fuse box E1 E7 Stop light switch (+)
Horn (-) E3 E4 Turn indicator switch (Horn
(+))
(+))
Turn indicator switch (right) F1 F9 Front right /side turn indicator
Turn indicator switch (left) F3 F10 Front left /side turn indicator
Connection to F1-F9 F5 Instrument panel (Turn indica-
tor warning light)
tor warning light)
Handbrake switch G1 G5 Instrument panel (handbrake
warning light)
Instrument panel (Brake oil
level warning light)
Fuel level transmitter (+) H2 H3 Instrument panel (Fuel gauge)
Oil pressure switch (+) H4 H5 Instrument panel (Oil pressure
warning light)
Instrument panel (Coolant
temp. gauge)
(+)
warning light)
J /B C (Windscreen wiper fuse) I1 I2 Windscreen wiper motor (+)
ES - 210
From A
screen wiper (+1))
shield washer)
screen wiper (+))
Rear window wiper switch
(rear window washer)
I10 I11 Rear window washer motor (-)
Rear window wiper switch (+) I12 I13 Rear window wiper motor (-)
Connection to -19 I14 Rear window wiper motor (+)
Connection to -19 I15 Rear window washer motor (+)
J /B C (Int. windscreen wiper
relay: S)
J /B C (Defroster fuse (L)) K1 K2 Defroster switch (+)
Defroster switch (-) K3 K4 Defroster (+)
J /B (Heater fuse (L)) K5 K6 Heating motor (+)
Heating fan switch (H1) K7 K8 Heating motor (-)
J /B C (Heating fuse (L)) K36 K14 Heating switch (B)
Connection to K12-K13 KA1 Diode (output) (rear fog light
switch)
Radiator fan relay (L) L17 L21 Coolant temperature sensor
(LO)
Fuse engine 20A L2 L16 Radiator fan relay (B)
Connection to Z32-Z8 L10 Radiator fan motor (-)
Engine cooling motor (-) L28 L19 Engine cooling motor relay (+)
Front right chassis ground Z1A L20 Engine cooling motor relay (-)
No.1 - No.2 connection L25 Radiator fan relay (+)
ES - 211
From A
Connection to Z32-Z8 L22 Radiator fan relay
EFI fuse No. 1 L41A L41 R/B (Main relay (+B))
Connection to L17-L21 L46 EFI ECU (AT)
Main fuse (B) M1 M2 F/L Main fuse
Main fuse (L) N1 N2 J /B A (Key switch (B))
Key switch (IG) N7 N15 J /B A (Key switch IG)
Connection to N7-N15 N16 J /B A (Key switch (IG1 ))
EFI F/L N35 N45 EFI fuse No. I
Connection to L48-L42 N38 Diagnostic check (IG2)
Connection to N1-N2 N39 Fuse (Fog light)
J /B A (ACC fuse (L)) R1 R2 Cigarette lighter (+)
EFI ECU - diagnosis (W) X2 T4 Instrument panel (Diagnosis)
EFI ECU - speed (SPD) X4 H38 Instrument panel (Speed sen-
sor speedometer)
Diagnostic check (VF) X20 X21 EFI ECU (VF)
Connection to L41A-L41 X23 IEFI ECU (BAT)
F/B (Fuel pump relay (L)) X124 IEFI ECU (BAT)
EFI ECU (H/L) X18 X152 Diode (IN)
ES - 212
From A
Instrument panel (T) X57 X266 EFI ECU (T)
EFI ECU (SIO) X268 X269 Diagnostic check (SIO)
Connection to Z1 -72 Z3 Instrument panel (Ground)
Connection to Z1 -Z2 Z10 Front right /side turn indicator
(-)
Connection to Z32-Z8 Z11 Front left/side turn indicator (-)
Connection to Z1 -Z2 Z14 Rear window washer switch (-)
Connection to Z1 -Z2 Z15 Rear window wiper switch (-)
Connection to Z1 -Z2 Z16 Defroster switch (-)
Connection to -Z5 Z33 Right license plate light (-)
Connection to Z1 -Z2 Z85 R/B (Main relay (-S))
tuator (-)
tuator (-)
Connection to ZB1-ZB2 ZB3 Resistance (R1)
Resistance (R1) ZB4 ZC3 Headlight aiming switch
Connection to Z1 -Z2 ZB7 Windscreen wiper (-)
Connection to Z1 -Z2 ZC1 Instrument panel
ES - 213
From A
Connection to Z1 -Z2 ZC2 Instrument panel
Connection to Z5 Z35 Rear right lights (-)
LEFT HAND DRIVE VAN:
1. main relay box and fuel pump
2. brake fluid level switch
3. courtesy light switch
4. sound alarm (buzzer)
5. left headlight adjustment actuator
8. left headlight
9. Horn
10. left fog light
11. Front left /side turn indicator
12. headlight adjustment switch
13. fog light switch
14. rear window wiper
ES - 214
15. rear fog light switch
16. stop light switch
18. Fog light fuse
20. flashing light switch
22. front fog light relay
23. windshield washer motor
24. rear window wiper motor
25. coolant temperature sensor
26. radiator fan relay
27. main fuse
30. fuel and low fuel gauge
31. fuel pump
32. to the chassis cable harness
33. Diode
34. Diode
35. radiator electric fan motor
37. ECU control unit
38. cigarette lighter
39. radio
40. radio
41. front right /side turn indicator
42. electric heater fan switch
43. right fog light
44. right headlight
45. right headlight adjustment actuator
46. front right position light
47. front right chassis ground
49. electric heater motor
50. resistance component (heating)
51 EFI fuses No. 1 - No. 2
ES - 215
53. windscreen wiper motor
55. instrument panel
56. key switch
From A
ing (HU))
ing (HL))
warning light)
Left headlight fuse (B) A21 A8 J /B C (Light fuse: L)
Right headlight (+B) A9 A24 Right Headlight fuse (B)
warning light+1 )
Left headlight (+B) A11 A23 Left headlamp fuse (L)
Right Headlight fuse (B) A22 A14 J /B C (Light fuse: L)
Turn indicator switch (emer-
gency)
A19 A39 Instrument panel (Emergency
warning light)
Connection to A11 -A23 A61 Left headlight aiming (+)
Right headlamp aiming (0) A56 A63 Left headlight aiming (0)
ES - 216
From A
(-))
Fog light switch B21 B16 Fog light relay
Connection to B19-B22 B23 Left fog light
Turn indicator switch (Fog
lights)
Connection to B1-B2 C4 Heater switch (lighting)
J /B C horn fuse (L) E1 E7 Stop light switch (+)
Horn (-) E3 E4 Turn indicator switch (Horn +))
(+))
Right turn indicator switch F1 F9 Front right /side turn indicator
Left turn indicator switch F3 F10 Front left /side turn indicator
Connection to F1-F9 F5 Instrument panel light (Turn in-
dicator warning light)
tor warning light)
Handbrake switch G1 G5 Instrument panel (Handbrake
warning light)
Instrument panel (Brake oil
level warning light)
Fuel level transmitter H2 H3 Instrument panel (fuel gauge)
Oil pressure switch (+) H4 H5 Instrument panel (Oil pressure
warning light)
ES - 217
From A
Instrument panel (cooling tem-
perature gauge)
(+)
warning light)
Connection to B1-B2 H50 Sounding mechanism (Lights
on)
Sounding mechanism (Lights
on)
H51 H52 Diode (input)
Diode (output) H53 D2 Courtesy light switch (+)
Connection to B19-B22 B24 Diode (input) (Rear fog light
switch)
Connection to A22-A14 B25 Diode (output) (Rear fog light
switch)
J /B C (Windscreen wiper fuse) I1 I2 Windscreen wiper motor (+)
screen wiper (+1))
shield washer)
screen wiper (+2))
Rear window wiper switch
(rear window washer)
I10 I11 Rear window washer motor (-)
Rear window wiper switch (+) I12 I13 Rear window washer motor (+)
Connection to -I9 I14 Rear window wiper motor (-)
Connection to -I9 I15 Rear window wiper motor (+)
J /B C (Int. windscreen wiper
relay: S)
J /B C (defroster fuse (L)) K1 K2 Defroster switch
Defroster switch (-) K3 K4 Defroster (+)
J /B C (Heater fuse (L)) K5 K6 Heating motor (+)
Heating fan switch (H]) K7 K8 Heating motor (-)
ES - 218
From A
J /B C (Heating fuse (L)) K36 K14 Heating switch (B)
Connection to K12-K13 KA1 Diode (output)
Radiator fan relay L17 L21 Coolant temperature sensor
FUSE ENGINE 20A L2 L16 Radiator fan motor (B)
Connection to Z32-Z8 L10 Radiator fan relay (L)
No.1 - No.2 connection L25 Radiator fan thermal sensor
(+)
Connection to Z32-Z8 L22 Radiator fan relay (-)
EFI fuse No. 1 L41A L41 R/B (Main relay (+E))
Connection to L17-L21 L46 EFI ECU (A/T)
Main fuse (B) M1 M2 F/1 Main fuse
Main fuse (L) N1 N2 J /B A (Key switch (E))
Key switch (IG) N7 N15 J /B (Key switch IG)
Connection to N7-N 15 N16 J /B A (Key switch (IG1 ))
EFI F/L N35 N45 EFI fuse No. 1
Connection to L48-L42 N38 Diagnostic check (IG2)
J /B C (ACC fuse (L)) R1 R2 Cigarette lighter
ES - 219
From A
EFI ECU - diagnosis (W) X2 T4 Diagnosis instrument panel
(Diagnosis)
EFI ECU - speed (SPD) X4 H38 Speed sensor instrument pan-
el (Speedometer)
Instrument panel (VF) X20 X21 EFI ECU (VF)
Connection to L41A-L41 X23 EFI ECU (BAT)
Connection to K3-K4 X124 EFI ECU (DEF)
EFI ECU (H/L) X18 X152 Diode (IN)
Diagnostic check (T) X57 X266 EFI ECU (T)
EFI ECU (S10) X268 X269 Diagnostic check (SIO)
Connection to Z1 -Z2 Z3 Instrument panel (Ground)
Connection to Z1 -Z2 Z11 Front right side turn indicator
(-)
Connection to Z32-Z8 Z12 Front left side turn indicator (-)
Connection to Z1 -Z2 Z14 Rear window washer switch (-)
Connection to Z1 -Z2 Z15 Rear window wiper switch (-)
Connection to Z1 -Z2 Z16 Defroster switch (-)
Connection to Z1 -Z2 Z19 Fog light switch
Connection to Z1 -Z2 Z20 Right fog light
Connection to Z1-Z2 Z21 Left fog light
Connection to Z1 -Z2 Z22 Fog light relay
Connection to Z1 -Z2 Z26 Cigarette lighter (-)
ES - 220
From A
Connection to Z1 -Z2 Z85 R/B (Main relay (-S))
tuator
tuator
Connection to Z1 -Z2 ZB3 Resistance (R1)
Connection to Z1 -Z2 ZB7 Windscreen wiper motor (-)
Connection to No.1 - No.2 N39 Fog light fuse
Cablaggio cruscotto (Tipper-guida sinistra)
ES - 221
TIPPER:
1. Main relay block
2. Brake fluid level switch
3. Courtesy light switch
4. Sound alarm (buzzer)
5. Headlight adjustment switch
6. Tipper warning light
7. Fog light switch
8. Tipper ascent/descent switch
9. Blinker
10. Rear fog light switch
13. Left headlight
14. Left headlight adjustment actuator
15. Horn
16. Left fog light
17. Front left/side turn indicators
18. Key switch
19. Instrument panel
20. Loudspeaker
21. Stop light switch
23. Fog light fuse
24. J /B C connection
25. Fog light relay
26. Front headlight fuse Left (10A)
28. Flashing light switch
29. Front windscreen wiper motor
30. OBD diagnostic check
31. Radiator cooling electric fan
32. Sound alarm (tipper)
33. Windshield washer electric pump motor
34. Radiator electric fan thermoswitch
35. Radiator fan relay
36. Main fuse (60A)
ES - 222
37. to the engine compartment main cable harness
38. to the injection cable harness
39. Limit switch (tipper descent)
40. Tipper pump solenoid valve
41. Rear oxygen probe
42. Tipper electric pump relay
42 B. To the battery positive (+) cable harness
43. Fuel pump
44. Fuel level sensor
45. Rear right lights
47. Chassis ground
48. Right license plate light
49. Left license plate light
50. Rear fog light
51. Rear left lights
52. Diode
53. Diode
55. EFI ECU
56. EFI fuse No.1 - EFI fuse No. 2
57. 12V Acc. socket / Cigarette lighter
58. Car radio
59. Heater electric fan switch
60. Right headlight adjustment actuator
61. Right fog light
62. Front right/side turn indicator
63. Right headlight
64. Front right position light
65. Front right chassis ground
ES - 223
INDEX OF TOPICS
ENGINE EN
Engine type 2
Engine mechanism
E.G.R. circuit intake duct
Inlet manifold removal
THE INLET MANIFOLD CAN BE REMOVED TO-
GETHER WITH THE THROTTLE BODY, EGR
VALVE, EGR MODULATOR AND INJECTORS,
IF NECESSARY.
1. Detach the suction pipe from the throttle body.
2. Remove the bolts and fixing nuts on the EGR
valve and on the EGR vacuum modulator.
3. Remove the bolts and fixing nuts on the throttle body and gasket.
KEY:
A= Throttle body
B= Gasket
PORTER 1.3 16V Engine
EN - 225
4. Take out the nut fixing the delivery pipe, then
remove the delivery pipe.
CAUTION
LEAVE THE INJECTOR ON THE INLET MANIFOLD SIDE.
BE CAREFUL NOT TO LET THE INJECTORS FALL. PLACE
A CLOTH OR A SIMILAR OBJECT UNDER THE INJECTOR
BECAUSE FUEL MAY COME OUT.
5. Remove bolts and nuts fixing the inlet manifold
by undoing them evenly in two or three stages,
according to the sequence indicated in the figure.
6. Remove the inlet manifold.
7. Remove the gasket.
Inlet manifold fitting - 1
1. Fit a new inlet manifold gasket to the cylinder
head.
2. Fit the inlet manifold on the cylinder head.
CAUTION
- DO NOT INTERFERE WITH OTHER PARTS.
3. Place bolts and nuts fixing the inlet manifold.
By-Pass pipe
Oil pressure switch terminal
4. Tighten bolts and nuts fixing the inlet manifold
evenly to the prescribed torque, in two or three
stages, according to the sequence indicated in the
figure on the right.
Cylinder head - Inlet manifold 15 22
Engine PORTER 1.3 16V
EN - 226
5. Fit the inlet manifold supports and tighten the
fixing bolts.
6. Fit the engine wire ground lead to the inlet mani-
fold.
7. Connect the fuel inlet and reverse fuel pipe.
8. Connect the water pipe.
9. Connect the blow-by pipe, suction pipes and
throttle cable.
10. Fit the injector vibration insulators and delivery
pipe thermal insulators.
11. Fit the injectors on the inlet manifold.
12. Fit the delivery pipe.
13. Tighten the fixing nuts.
Inlet manifold - Fuel delivery pipe 611
EN - 227
14. Fit the throttle body interposing a new gasket.
15. Tighten the bolts and fixing nuts.
Inlet manifold - Throttle body 1522
Inlet manifold fitting -2
16. Fit the EGR valve on the inlet manifold inter-
posing a new gasket.
Inlet manifold - EGR valve 1522
17. Fit the EGR pipe on the EGR valve.
EGR valve - EGR pipe 4771
18. Fit the EGR pipe in the inlet manifold interpos-
ing a new gasket.
Inlet manifold - EGR pipe 1522
EN - 228
19. Connect the fittings to the respective pipes.
20. Engine cable installation
Connect the engine wire connector to
the parts listed below:
- Ignition coils
- Injectors
- Pressure sensor
- Throttle position sensor
- Intake air temperature sensor
- VSV (Vacuum Switching Valve) - idle speed
- Oxygen sensor
- Camshaft sensor
- VSV (Vacuum Switching Valve) - bleeding
- Ignition system
- Engine coolant temperature sensor
- VSV (Vacuum Switching Valve) EGR (Recircu-
lation of Exhaust Fumes)
- Ground cables
- Handbrake switch
- Oil pressure switch
Fit the terminals on each bracket.
21. Fit the toothed belt.
22. Fit the alternator.
23. Add coolant.
24. Adjust valve clearance with temperature.
EN - 229
Exhaust pipe
Manifold check
1. Check for any deformation of the head-cylinder connection surface with the exhaust manifold, using
a ruler with rectilinear edge and a thickness gauge.
Characteristic
Maximum deformation limit:
0.1 mm
If the deformation exceeds the maximum value,
replace the exhaust manifold No.1.
2. Check the contact surface of the inlet manifold
with the head.
Characteristic
Maximum deformation limit:
0.1 mm
Exhaust manifold removal
1. Remove the front exhaust pipe from the exhaust
manifold.
2. Remove the oxygen sensor from the exhaust
manifold.
EN - 230
3. Loosen bolts and nuts fixing the exhaust mani-
fold evenly in two or three stages, according to the
sequence indicated in the figure on the right.
4. Remove the exhaust manifold from the cylinder
head avoiding any interference with other parts.
Exhaust manifold fitting
1. Fit the new exhaust manifold gasket.
2. Fit the exhaust manifold on the cylinder head.
N.B.
- PAY ATTENTION NOT TO INTERFERE WITH OTHER
PARTS.
3. Place bolts and fixing nuts and tighten them
evenly in two or three stages, according to the se-
quence indicated in the figure on the right.
4. Fit the oxygen sensor on the exhaust manifold.
5. Connect the front exhaust pipe to the exhaust
manifold, interposing a new gasket.
6. Tighten the bolt fixing the front exhaust pipe to
the prescribed torque.
- DO NOT REUSE OLD GASKETS. - BE EXTREMELY CARE-
FUL TO AVOID DAMAGING THE CABLE HARNESS DUR-
ING FITTING OPERATIONS.
EN - 231
Cylinder head - Exhaust manifold 35 53 Ex-
haust manifold for oxygen sensor 29.4 39.2 Nm
Exhaust manifold - Front exhaust pipe 4262
Alternator drive belt
Tension adjustment
1. Screw the adjustment bolt until the driving belt
bending reaches the indicated value. Check by
pressing the belt central part between the water
pump pulley and the alternator pulley, applying a
force equivalent to 98 N.
KEY:
1. Water pump pulley
2. V-belt
3. Shaft pulley
4. Alternator pulley
5. Force application point
6. Straight ruler
7. Bending degree
Belt bending specified value:
With the application of a force equivalent to 98 N at the indicated point.
Characteristic
New belt:
3.5 5.5 mm
Belt bending specified value:
with the application of a force equivalent to 98 N
at the indicated point.
Characteristic
Used belt:
4.5 6.5 mm
2. Tighten the alternator locking screws.
Generator fixing screws - M8 1822 Generator fixing screws - M10 2832
EN - 232
Driving belt test
1. Visual inspection of the driving belt.
Visually check the belt for any traces of separation
of the upper or lower part of the belt from the ad-
hesive rubber, belt core separations from the
sides, belt core ravelling, adhesive rubber weft
ravelling, cracks or separations of ribs, tearing or
cracking in the belt internal ribs. Replace the driv-
ing belt, if necessary.
2. Driving belt tension test. Measure the driving
belt deflection (bending) when a 98 N (10 Kgf)
force is applied at the middle point of the belt, be-
tween the alternator pulley and the water pump
pulley.
Characteristic
Rated deflection of the New Belt (with a 10 kg
force applied at the indicated point):
3.5 - 5.5 mm
Rated deflection of the Used Belt (with a 10 kg
force applied at the indicated point):
4.5 - 6.5 mm
KEY:
A =Water pump pulley
B =Alternator pulley
Adjust driving belt tension, if necessary.
A "NEW BELT" IS A BELT THAT HAS BEEN USED FOR LESS THAN FIVE MINUTES ON
A RUNNING ENGINE.
A "USED BELT" IS A BELT THAT HAS BEEN USED FOR MORE THAN FIVE MINUTES
ON A RUNNING ENGINE.
AFTER FITTING A NEW BELT, LET THE ENGINE RUN FOR AT LEAST FIVE MINUTES
AND THEN CHECK TENSION AGAIN.
EN - 233
Flywheel
Flywheel test
1. Visually inspect the flywheel to detect any
cracks, wear or other damage.
2. Visually inspect the crown gear to detect any
worn areas, cracks or other damage. Replace the
crown gear, if necessary.
Crown gear replacement
1. Position the flywheel on an adequate wooden
block. Remove the crown gear by using a punch
together with a hammer.
2. Position a new crown gear on the flywheel in a
horizontal position.
3. With a torch, heat the crown gear evenly, until
due to its own weight, it adapts to the flywheel.
N.B.
- DO NOT FORCE THE CROWN GEAR.
- DO NOT COOL THE CROWN GEAR QUICKLY BY USING
WATER.
4. Let the crown gear gradually cool down.
EN - 234
Driving pulley
Crankshaft pulley test
1. Visually check the crankshaft pulley
Check for deformations, wear or
cracks on the crankshaft pulley attach-
ment seat.
Check for any deformations or wear on
the belt contact surface. Replace the
crankshaft pulley, if necessary.
Crankshaft pulley flange fitting
Fit the crankshaft pulley flange so that the input
edge for the belt is positioned towards the oil
pump.
Crankshaft pinion fitting
Fit the timing belt pinion.
Fitting the timing pinion fixing screw
Fit the timing pinion fixing screw Tighten the screw
to the specified torque.
- AVOID THE ROTATION OF THE CRANKSHAFT BY USING
THE SPECIAL TOOL BELOW.
Specific tooling
020184Y FLYWHEEL LOCKING TOOL
EN - 235
Timing belt and gears
KEY:
1. Alternator-water pump belt
3. Pulley-crankshaft assembly
4. Upper cover
5. Lower cover
6. Tensioner
7. Timing belt
Timing belt replacement
Initial operations
1. Remove the water pump V-belt, undoing the al-
ternator support screws.
2. Remove the water pump belt.
3. Remove the water pump pulley, undoing the fix-
ing screws.
EN - 236
4. Remove the crankshaft pulley.
SET THE GEARSHIFT LEVER TO THE FOURTH GEAR, SO
AS TO AVOID THE ROTATION OF THE CRANKSHAFT.
5. Disconnect the minimum oil pressure switch
connector and remove the screws locking the elec-
tronic cable supporting brackets.
6. Remove the timing belt cover, removing the
three remaining fixing screws.
Timing belt removal
IF THE TIMING BELT IS ALREADY USED,
WITH A PIECE OF CHALK MARK AN ARROW
ON THE BELT INDICATING THE BELT ROTA-
TION DIRECTION.
WARNING
DO NOT ATTEMPT TO REMOVE THE TIMING
BELT WITH A SCREWDRIVER, OR ANYTHING
SIMILAR, DURING REMOVAL OR FITTING.
PREVENT THAT THE BENT COMES INTO
CONTACT WITH OIL OR WATER.
DO NOT BEND, TWIST OR TURN THE BELT
UPSIDE DOWN.
EN - 237
7. Turn the crankshaft until the "F" mark on the
camshaft pulley matches the indicator of the head
- cylinder cover.
8. Loosen the screw fixing the timing belt tension-
er. Move the tensioner towards the left and lock it
temporarily.
9. Remove the timing belt.
DO NOT BEND, TWIST OR TURN THE BELT
UPSIDE DOWN.
PREVENT THAT THE BENT COMES INTO
CONTACT WITH OIL, WATER OR VAPOURS.
EN - 238
If the belt has defects similar to those shown in the
figures, check the following points and replace the
belt, if necessary.
1. Early breaking
- Check for a proper fitting.
- Check that the timing gear cover gaskets are not
damaged and that they are properly fitted.
2. If the belt teeth are cracked or damaged, check
that the camshaft is not jammed.
3. If the surface of the belt has clear signs of wear
or breaking, check if there are notches on one side
of the tensioner pulley.
4. If only one side of the belt is worn and damaged,
check the crankshaft pulley flange.
5. If belt teeth are worn, check for possible damage
on the cover gasket, or if the gasket has been
properly fitted. Check there are no foreign bodies
on the pulley teeth.
EN - 239
Belt tensioner
Belt tensioner pulley check
If the tensioner is not damaged, check if the rele-
vant bearing has an excessive clearance.
CHECK THAT PULLEYS TURN FREELY
(WITHOUT J AMMING).
CHECK THAT THE BELT CONTACT SUR-
FACE IS NOT DAMAGED.
REPLACE THE BELT TENSIONER PULLEY, IF
NECESSARY.
NEVER WASH THE BELT TENSIONER PULLEY
Timing belt tensioner spring check
1. Check the unloaded spring length.
Characteristic
Unloaded length:
not exceeding 46.5 mm
2. Check the spring tension when the spring is
tensioned up to the length corresponding to the
working position.
Smontaggio puleggia sull'albero motore
Crankshaft pulley and flange test
1. Measure the pulley outside diameter, using a gauge.
Characteristic
Crankshaft pulley wear limit (mm)
59.3
EN - 240
If the value measured is lower than the rated value,
replace the pulley.
2. Visually check for possible damage on the pul-
ley. If there is damage, replace the pulley.
3. Carry out a visual inspection of the crankshaft
pulley flange, to check for possible bending, wear
or damage.
If there is damage, replace the flange.
Crankshaft pulley removal
2. Remove the screw locking the crankshaft pulley
LOCK THE CRANKSHAFT WITH THE SPECIAL TOOL FIT-
TED INSTEAD THE STARTER MOTOR. DURING A SERV-
ICE ON A BENCH, USE THE SPECIAL TOOL.
Specific tooling
020397Y FLYWHEEL LOCK WRENCH (ENGINE
ON VEHICLE)
EN - 241
IF THERE WAS A DIFFICULTY DURING THE CRANK-
SHAFT PULLEY REMOVAL USE THE SPECIAL TOOL.
4. Remove the timing belt pulley flange.
Refitting pulley on crankshaft
Crankshaft pulley fitting
1.Fit the crankshaft pulley flange with the edge
bending facing towards the oil pump. Align the
holes with the toothing cavity.
2. Fit the pulley on the crankshaft, and align it with
the key slot.
3. Fit the pulley fixing screw on the crankshaft.
4. Tighten the fixing screw to the prescribed tor-
que.
AVOID CRANKSHAFT ROTATION.
USE THE SPECIAL TOOLS PROVIDED
Specific tooling
020397Y FLYWHEEL LOCK WRENCH (ENGINE
ON VEHICLE)
Crankshaft - timing system pulley screw 88 98
EN - 242
Removal - Refitting timing pulley
Camshaft pulley removal
2. Remove the cylinder head cover.
3. Camshaft pulley removal. Using a special tool,
prevent the camshaft pulley from rotating, then un-
do the three pulley fixing screws. Then, remove the
camshaft pulley.
Specific tooling
020172Y TOOL TO LOCK THE TIMING BELT
PULLEY
Camshaft pulley check
1. Measure the pulley outside diameter with a
gauge.
Characteristic
Timing shaft pulley wear limit
119.8
If the value measured is lower than the specified value, replace the pulley.
2. Visually check that the timing belt pulley is not
damaged. Replace, if necessary.
EN - 243
Camshaft pulley fitting
1. Fit the camshaft pulley on the camshaft, so that
the "F" mark remains visible and matches the po-
sition notch.
2. Fit the screws locking the pulley, avoiding that
the latter rotates, inserting a steel rod inside the
pulley hole or using the special tool.
DO NOT ROTATE THE CAMSHAFT
BE CAREFUL NOT TO DAMAGE THE CYLIN-
DER HEAD CLOSING SURFACE GASKET.
SCREWS AS WELL AS THREADED HOLES
MUST BE DRY DURING TIGHTENING.
Specific tooling
020172Y TOOL TO LOCK THE TIMING BELT
PULLEY
Timing system pulley screws 1522
Tension spring connection
Connect the tension spring to the timing belt ten-
sioner.
Attach the tension spring ring to the pin.
Fit the belt tensioner and fixing screw.
ATTACH THE SPRING RING FIRMLY ON THE
RELEVANT PIN.
MAKE SURE THAT THE PIN ON THE OIL
PUMP IS FITTED IN THE TENSIONER HOLE.
Valve timing - Belt refitting
Timing belt fitting
1. Temporarily fit the head cover.
EN - 244
2. Place the timing shaft pulley with reference point
B matching the head coupling surface with the
cover.
3. Match reference point C of the crankshaft pulley
with indicator D located in the oil pump casting.
4. Fit the belt so that the two coloured marks match
the respective pulley references.
DO NOT SPILL OIL, WATER ETC. ON THE
TIMING BELT.
DO NOT ATTEMPT TO REMOVE THE BELT
WITH A SCREWDRIVER OR ANYTHING SIMI-
LAR.
WHEN REFITTING A BELT, THERE MUST BE
35 TEETH BETWEEN THE CRANKSHAFT
PULLEY AND THE CAMSHAFT PULLEY REF-
ERENCES.
WHEN REFITTING A USED BELT, KEEP THE
SAME ROTATION DIRECTION (SEE DEFLEC-
TION APPLIED DURING REMOVAL).
KEY:
A: Reference on head cover
B: Reference on timing pulley
C: Reference on crankshaft pulley
D: Reference on oil pump casting
F: "F" reference mark on timing pulley external side
5. Loosen the tensioner locking bolt. Tension the
belt. Temporarily tighten the locking screw.
MAKE SURE THAT THERE IS NO CLEARANCE ON THE
TIGHT SECTION OF THE BELT (THE OPPOSED SIDE TO
THE TENSIONER).
6. Rotate the crankshaft by 3~4 turns in the normal
direction of rotation.
After aligning the belt, continue in the rotation di-
rection until the letter "F" of the pulley is positioned
three teeth before the reference located in the
head cover.
NOW, DO NOT TURN THE CRANKSHAFT IN THE OP-
POSED DIRECTION.
MAKE SURE THAT THE BELT IS NOT BENT IN THE SEC-
TION BETWEEN THE CRANKSHAFT PULLEY AND THE
CAMSHAFT PULLEY.
EN - 245
7. Loosen the tensioner locking screw.
8. Further turn the crankshaft in the regular direc-
tion until reference "F" of the camshaft pulley
matches the indicator (notch) placed on the head
- cylinder cover.
NEVER TURN THE CRANKSHAFT IN THE RE-
VERSE DIRECTION.
NEVER TURN THE CRANKSHAFT BEYOND
THE POINT WHERE REFERENCE "F" OF THE
CAMSHAFT PULLEY MATCHES THE INDICA-
TOR.
IF THE CRANKSHAFT IS TURNED TO THE
REVERSE DIRECTION OR TURNED SO AS
TO EXCEED THE POINT DESCRIBED ABOVE,
TIGHTEN THE TENSIONER LOCKING
SCREW TEMPORARILY AND REPEAT ALL
THE OPERATIONS FROM POINT (5) ON-
WARDS.
9. Tighten the belt tensioner locking screw to the
specified torque value.
Timing system belt tensioner 2944
10. Make sure that the crankshaft pulley as well as
camshaft pulley reference points, match the cor-
responding indicators.
If the reference does not match the indicator, re-
peat the operations from point 2. onwards.
KEY:
A: Reference on head cover
B: Reference on timing pulley
EN - 246
C: Reference on crankshaft pulley
D: Reference on oil pump casting
F: "F" reference mark on timing pulley external side
Valve timing - Belt tensioning
Belt tensioning check
Make sure that deflection is within the specified value.
Characteristic
Belt deflection:
5 mm with a 8 16N force applied
If belt tension does not comply with the specified
values, repeat the operations carried out for ten-
sioning.
Fitting the upper and lower cover of the timing
belt
WARNING
BE CAREFUL THAT THE SCREWS ARE PROPERLY FIT-
TED. THE BLACK SCREW IS PLACED TOGETHER WITH
THE SUPPORT FOR THE CABLE, IN THE CLAMP CLOSER
TO THE MINIMUM OIL PRESSURE SWITCH.
Timing belt cover screw 24
1. Fit the oil pressure switch wire and tighten the
wire clamps.
2. Connect the oil pressure switch connector.
EN - 247
3. Fit the crankshaft pulley with the relevant fixing
bolt. Tighten the bolt to the prescribed torque.
N.B.
ENGAGE THE 4TH GEAR TO AVOID CRANKSHAFT RO-
TATION.
Crankshaft pulley - transmission screws 2029
4. Fit the water pump pulley and tighten the rele-
vant fixing bolts.
5. Fit the driving belt.
6. Adjust the driving belt tension.
Oil pump
Removal
Oil pump removal
1. Remove the oil pump cover.
2. Remove the sealing ring with a punch.
N.B.
- THE SEALING RING CAN BE REMOVED AND REFITTED
DIRECTLY ON THE VEHICLE WITH THE SPECIAL TOOL.
EN - 248
3. Remove the oil pump rotors.
4. Take out the split pin keeping the spring holder
cap in its seat.
- PLACE AN ADEQUATE PROTECTIVE CLOTH ON THE
SPRING HOLDER, TO AVOID THAT THE SPRING JUMPS
OUT.
5. Remove the cap, the spring and piston.
- WASH THE PARTS REMOVED USING SOLVENT.
6. Checking each single part
Check if the valve body is damaged.
EN - 249
Check if rotors are damaged.
Check if the valve piston is damaged.
Replace the piston if it is damaged.
Check if the valve seat on the oil pump body is
damaged.
Check the spring for deformations;
measure its unloaded length as well.
Replace the spring if deformations are detected,
or its unloaded length is below the specified value.
Characteristic
Unloaded length value according to specifica-
tions:
57 mm
Check if the spring holder is damaged.
Replace the holder if it is damaged.
EN - 250
Apply engine oil onto the pressure-reg-
ulating valve.
Insert the piston in the oil pump body.
Check if the piston moves regularly.
Replace the oil pump body, if the piston does not
move smoothly and without problems.
7. Pump body-rotor coupling check.
Apply an oil film onto the rotor coupling
surfaces.
Fit the rotors on the oil pump body, so that the
identification points are visible from the outside.
Measure clearance between the oil
pump body and the external rotor with
a thickness gauge.
Replace the oil pump if the rotor clearance ex-
ceeds the specified value.
Characteristic
Body clearance:
0.20 - 0.28 mm
Measure clearance between lobes
with a thickness gauge.
Replace rotors if clearance exceeds the specified
value.
Characteristic
Lobe clearance:
0.16 - 0.24 mm
EN - 251
Measure the axial clearance of rotors
with the pump body using a ruler with
rectilinear edge and a thickness
gauge.
Replace the oil pump if the axial clearance ex-
ceeds the specified value.
Characteristic
Axial clearance:
0.035 - 0.085 mm
8. Check for any worn areas on the pump cover,
corresponding to the surface coupling with rotors.
Replace the oil pump cover if signs of wear are
detected.
Timing side oil sealing ring replacement
1) Sealing ring removal
Remove the sealing ring from the oil pump, using
a punch.
2) Timing side sealing ring fitting
Insert a new sealing ring using the following spe-
cial tool.
Specific tooling
020384Y TOOL FOR TIMING SIDE CRANK-
SHAFT OIL SEAL
EN - 252
Refitting
Oil pump fitting
1. Apply oil onto the pressure-regulating valve.
Then, insert the valve piston in the specific oil
pump body seat.
2. Insert the spring and its cap in the oil pump body.
- WASH THE PARTS TO BE FITTED USING SOLVENT. DRY
THEM WITH COMPRESSED AIR. - WHEN COMPRESSED
AIR IS USED, PROTECT EYES WITH PROTECTIVE GOG-
GLES. - FIT THE SPRING CAP PROPERLY.
3. Insert a new split pin in the holder. Lock by
opening the split pin.
4. Apply oil onto rotors. Fit the rotors in the pump
body, so that rotor references are visible from the
outside.
5. Fit the oil pump cover. Tighten the cover to the
specified torque values.
EN - 253
6. Insert a new sealing ring in the right position with
the following special tool.
- BE CAREFUL NOT TO DAMAGE THE OIL PUMP DURING
FITTING.
- MAKE SURE THAT THE SEALING RING IS NOT PLACED
DIAGONALLY.
Specific tooling
SHAFT OIL SEAL
7. Turn rotors by hand. Check that rotors turn free-
ly.
If rotor jamming is detected, carry out a pump
service.
N.B.
- THE FUNCTIONAL TEST PROCEDURE OF THE OIL PUMP
IS DESCRIBED IN THE 'LUBRICATION SYSTEM' SECTION .
Cylinder head assembly
Cylinder head unit
KEY:
1. Cylinder head cover
EN - 254
2. Camshaft
3. Rocking lever for valve
4. Valve guide
5. Cylinder head
6. Oil seal
7. Spark plug
8. Valve
9. Spring seat
10. Valve stem oil seal
11. Valve spring
12. Valve spring cap
13. Valve rocking lever
14. Camshaft toothed belt pulley
15. Spacer
16. Sealing ring
17. Gasket
18. Driving belt upper cover
19. Driving belt
20. Driving belt tensioner
21. Camshaft cap
22. Cylinder head gasket
23. Ignition coil assembly
24. Throttle body
25. EGR valve (Recirculation of Exhaust Fumes)
26. EGR vacuum modulator (Recirculation of Exhaust Fumes)
27. Inlet manifold
28. EGR pipe (Recirculation of Exhaust Fumes)
29. EGR pipe gasket (Recirculation of Exhaust Fumes)
A= Front
*: Non-reusable parts
EN - 255
Initial operations
Alternator removal
1. Remove the connector and cable on the alter-
nator rear side.
2. Remove the alternator with belt tension adjust-
ment bar.
Remove the driving belt.
Removal of the engine wire from the cylinder
head
Disconnect the engine wire connector
from the following parts:
1. Ignition coil
2. Injectors
3. Pressure sensor
4. Throttle sensor
5. Intake air temperature sensor
6. VSV (Vacuum Switching Valve) - idle speed
8. Oxygen sensor
9. Camshaft sensor
10. VSV (Vacuum Switching Valve) - bleeding
11. Ignition system
12- VSV (Vacuum Switching Valve) EGR (Recir-
culation of Exhaust Fumes)
13. Ground lead
14.Oil pressure switch
15. Handbrake switch
Disconnect the cable terminals.
Remove the engine wires from the cyl-
inder head.
EN - 256
Drain the coolant and detach water pipes.
Detach the delivery and reverse fuel pipe.
CAUTION
THE PRESSURE INSIDE THE FUEL DUCT IS
APPROX. 284 KPA HIGHER THAN THE AT-
MOSPHERIC PRESSURE.
THEREFORE, REMOVE THE PIPES GRADU-
ALLY TO AVOID FUEL SPRAYING.
Remove the inlet manifold.
Remove the exhaust manifold.
Pagina Manuale VTL
Exhaust pipe
Head removal
1. Remove the ignition coil unit from the cylinder
head cover.
EN - 257
2.Loosen bolts fixing the cylinder head cover even-
ly in two or three stages, according to the se-
quence indicated in the figure on the right.
3. Remove the oil filling pipe and cylinder head
cover.
4. Remove the camshaft pulley and camshaft sen-
sor.
DO NOT TURN THE CAMSHAFT WITHOUT
HELP.
AVOID DAMAGING THE CYLINDER HEAD
COVER GASKET SURFACE.
5. Loosen the bolts fixing the valve rocking lever
pin.
6. Remove the valve rocking lever pin together with the cylinder head rocking levers.
7. Remove the rocking levers, the spacer and crin-
kle washer from the valve rocking lever pin previ-
ously removed.
PLACE THE PARTS REMOVED IN ORDER SO AS TO OB-
SERVE THE ORIGINAL POSITIONS WHEN REFITTING.
EN - 258
8. Remove the camshaft supports, taking out the
relevant clamps.
Remove the camshaft from the head.
9. Loosen the head screws, operating evenly in
two or three stages, according to the sequence in-
dicated in the figure.
FAILURE TO OBSERVE THE INDICATION ABOVE MAY
CAUSE THE BREAKING OR DEFORMATION OF THE CYL-
INDER HEAD, AND ALSO ENGINE SEIZURE.
10. Remove the head fixing screws
REFERENCE:
- Screws (1) and (3) are shorter than the others.
Rated length of (1) and (3): 110 mm
Rated length of the other screws: 155 mm
11. Remove the head from the cylinder block.
REST THE HEAD ON SUITABLE WOODEN
SUPPORTS, TO AVOID DAMAGING THE
HEAD GASKET SUPPORTING SURFACE.
BE CAREFUL NOT TO LOSE THE SEALING
GASKET FITTED BETWEEN THE WATER
PUMP AND THE HEAD.
EN - 259
Pressure relief valve
EGR valve check
1. Apply a negative pressure of about 53 kPa (400
mmHg) to the chamber with diaphragm. At this
point, check that the MityVac device pointer is sta-
ble.
2. Close opening B, blow compressed air into
opening A. Check if there is no air continuity.
3. Close opening C and apply a negative pressure
of about 14.6 kPa (110 mmHg) to the EGR valve,
using the MityVac device. At the same time, check
if there is air continuity between points A and B.
4. Close section B and apply a negative pressure
of about 14.6 kPa (110 mmHg) to the EGR valve,
using the MityVac device. At the same time, check
if there is air continuity between points A and C.
Tappet cover gasket
Cylinder head cover inspection
1. Visually check the la cylinder head cover gasket.
Replace the gasket with a new one, if necessary.
Fit the cylinder head gasket on the cylinder head
cover so that the reference mark is facing towards
the inlet manifold.
2. Check that the spark plug pipe sealing rings are
not damaged. Replace the sealing rings, if neces-
sary.
Spark plug sealing ring replacement.
1. Remove the spark plug sealing rings with the
appropriate extractor.
EN - 260
2. Fit a new spark plug sealing ring with the special
tool recommended.
N.B.
- MAKE SURE THAT THE SEALING RING IS ADEQUATELY
POSITIONED.
- USE A SUITABLE WOODEN PIECE TO AVOID DAMAGING
THE CYLINDER HEAD COVER.
- BE CAREFUL NOT TO DAMAGE THE SEALING RING
PROTRUDING PART.
Specific tooling
020274Y Checking tool kit
Valve - tappet play
Valve clearance adjustment
Measure and adjust valve clearance when the pis-
ton of cylinders No.1 and No.4 is at the top dead
centre at the end of compression.
AS A RULE, VALVE CLEARANCE IS ADJUSTED WHEN
THE ENGINE IS HOT . " HOT ENGINE" MEANS THAT THE
COOLING WATER TEMPERATURE IS 75 85C AND THAT
THE ENGINE OIL TEMPERATURE IS ABOVE 65C. NEV-
ERTHELESS, ONCE THE ENGINE IS SERVICED, ADJUST
VALVE CLEARANCES WITH COLD ENGINE AND THEN
ADJUST AGAIN WITH HOT ENGINE AFTER WARMING UP
THE ENGINE.
Lock nut 16.7 22.5 Nm
VALVE CLEARANCES
Intake with hot engine 0.25 0.05 mm
Exhaust hot engine 0.33 0.05 mm
Intake with cold engine 0.18 mm
Exhaust with cold engine 0.25 mm
With rocking levers for valve of cylinder No.1 free (intake),
adjust the cylinder valves: 1-2
The piston of cylinder No.1 is at the top dead centre during compression (exhaust),
With rocking levers for valve of cylinder No.4 free (intake),
The piston of cylinder No.4 is at the top dead centre during compression (exhaust),
Adjust the cylinder valves: 2-4
EN - 261
Tappet pin
Rocking lever and pin check
1. Visually check the rocking lever to detect any
cracks, seizures or wear. Replace the rocking lev-
er if necessary.
2. If the contact surface between the cam and the
rocking lever is excessively worn, replace the rock-
ing lever.
3. Visually check the pin to detect any cracks, seiz-
ures or wear.
Replace the pin, if necessary.
KEY:
A =Intake
B =Exhaust
4. Pin and rocking lever coupling
With a dial gauge, measure the rocking
lever inside diameter according to two
directions perpendicular to each other.
With a micrometer, measure the pin
outside diameter in the coupling posi-
tion with the rocking lever. Measure in
two directions perpendicular to each
other.
Calculate clearance by deducting the pin diameter from the rocking lever diameter.
MEASURE THE PIN OUTSIDE DIAMETER IN THE COUPLING POSITIONS OF EACH ROCKING
LEVER.
Characteristic
Specification value clearance:
0.012 - 0.053 mm
Clearance value allowed:
0.08 mm
EN - 262
Reference:
Rocking lever identification.
On the intake rocking lever pin, seats
are included so as not to interfere with
the spark plug jacket.
On the intake side pin, there are
grooves for lubrication close to the
screw holes.
On the exhaust side pin, the grooves
are located far from the screw holes.
Pin fitting direction.
The pin must be fitted so that the side with the lon-
ger chamfer is facing towards the timing belt.
KEY:
C =Intake
D =Exhaust
E =Timing belt side
F =Spark plug jacket seat
- Rocking lever identification.
There are 4 different types of rocking levers: 2 for
the intake side and 2 for the exhaust side, as
shown in the figure.
- Pin and rocking lever dimensions.
Characteristic
Pin outside diameter:
19.468 - 19.488 mm
Rocking lever hole diameter:
19.500 - 19.521 mm
KEY:
F =Intake
G =Exhaust
H =No.1
I =No.2
L =No.3
M =No.4
EN - 263
Spacer and crinkle washer check
1. Measure the spacer unloaded width with a
gauge.
Characteristic
Minimum unloaded width:
22.0 mm
Replace the spacers with an unloaded width lower than the minimum unloaded width value.
2. Visually check the crinkle washers, to assess flattening condition or damage possibilities.
Replace the crinkle washers, if necessary.
Camshaft inspections
Camshaft check
1. Check for camshaft wear.
Rest both camshaft ends on two V-shaped blocks.
Place a dial gauge at the central point of a cam-
shaft support section.
Rotate the shaft by one turn, paying attention that
the shaft does not move in an axial direction. Read
the dial gauge during rotation.
Calculate the eccentricity; that is, the difference
between the maximum and the minimum reading.
Characteristic
Maximum eccentricity:
0.03 mm
If the eccentricity exceeds the maximum value, replace the camshaft.
EN - 264
2. Cam lobe height check
Measure, with a micrometer, the cam lobe height.
Characteristic
Rated height of the cam lobe during intake:
33.434 - 33.634 mm
Rated height of the cam lobe during exhaust:
33.17 - 33.37 mm
Minimum limit during intake:
33.2 mm
Minimum limit during exhaust:
33.0 mm
3. Checking the surface making contact with the
sealing ring
Check the surface to identify areas which are pos-
sibly worn.
Replace the camshaft if there are areas with ex-
cessive wear.
4. Checking the guiding groove of the cam angle
sensor
Visually check the groove where the cam angle
sensor is fitted, to verify that there is no damage.
Replace the camshaft, if the sensor groove is dam-
aged.
N.B.
IF THERE IS DAMAGE, ALSO CHECK THE CAM ANGLE
SENSOR DRIVE.
N.B.
BEFORE CHECKING, MAKE SURE THAT THE SHAFT IS RECTILINEAR.
1. Fit the camshaft on the head-cylinders.
EN - 265
2. Apply plastigauge onto each camshaft bearing.
3. Fit supports and rocking lever pins.
Tighten to the specified torque.
N.B.
EACH SUPPORT HAS AN IDENTIFICATION
NUMBER.
THE INTAKE ROCKING LEVER PIN CAN BE
IDENTIFIED BY THE SPARK PLUG J ACKET
MILLING.
THE ROCKING LEVER PINS MUST BE FITTED
WITH THE BIGGEST CHAMFER FACING TO-
WARDS THE TIMING SYSTEM SIDE.
MAKE SURE THAT THE THREADS OF
SCREWS AND HOLES ARE DRY.
Cylinder head - M 8 Camshaft 1317 Cylinder
head - M 10 Camshaft 2936
4. Remove the bearing covers and measure clearance.
Characteristic
Camshaft bearing coupling clearance (mm)
0.035 0.076 mm
limit accepted: 0.17 mm
If clearance exceeds the allowed limit, replace the
head and camshaft.
N.B.
ONCE CHECKING HAS FINISHED, REMOVE PLAS-
TIGAUGE. WASH THE CAMSHAFT AND SUPPORTS US-
ING SOLVENT.
EN - 266
Camshaft axial clearance test
1. Apply engine oil onto the camshaft bearings.
2. Fit the camshaft on the head.
Fit supports and rocking lever pins and lock them
N.B.
EACH SUPPORT HAS AN IDENTIFICATION
NUMBER.
THE INTAKE ROCKING LEVER PIN CAN BE
IDENTIFIED BY THE SPARK PLUG J ACKET
MILLING.
THE ROCKING LEVER PINS MUST BE FITTED
WITH THE BIGGEST CHAMFER FACING TO-
WARDS THE TIMING SYSTEM SIDE.
MAKE SURE THAT THE THREADS OF
SCREWS AND HOLES ARE DRY.
Cylinder head - M 8 Camshaft 1317 Cylinder
head - M 10 Camshaft 2936
3. Measure camshaft axial clearance, through a
dial gauge with magnetic base.
Specific tooling
020335y Magnetic support for dial gauge
Characteristic
Camshaft axial clearance (mm)
specified value: 0.1 0.25 mm
limit accepted: 0.45 mm
If axial clearance exceeds the allowed limit, replace the camshaft and head.
Characteristic
Seat width in the head:
4.10 - 4.20 mm
Camshaft collar thickness:
3.95 - 4.00 mm
EN - 267
Head removal/overhaul
Head Removal - Cylinders
1. Remove the water temperature sensor from the
cylinder head.
2. Remove the bracket for engine handling.
3. Remove the cotters and valve spring stop caps,
with the special tool.
Specific tooling
4. Remove the valve springs.
N.B.
POSITION THE PARTS REMOVED SO THAT THEIR ORIG-
INAL FITTING POSITIONS CAN BE EASILY IDENTIFIED.
5. Remove the valves.
N.B.
EN - 268
6. Remove the valve sealing rings
7. Remove the valve spring supporting caps.
N.B.
8. Wash the parts removed, except for the electrical and plastic parts. Dry them with compressed air.
Gasket residue removal
With a gasket scraper, remove each gasket resi-
due from the head and from manifold surfaces.
Head cleaning and check
1. With a soft brush and solvent, clean the head-
cylinders thoroughly.
Check that the head is even
2. With a precision ruler and a thickness gauge, check that the gasket surfaces which contact the block
and manifold are even.
EN - 269
LEVELNESS TOLERANCE
Block side: 0.10 mm
Inlet manifold side: 0.10 mm
Exhaust manifold side: 0.10 mm
Combustion chamber cleaning
With an iron brush, remove all the carbon deposits
from the combustion chamber.
BE CAREFUL NOT TO SCRATCH THE HEAD GASKET
CONTACT SURFACES.
EN - 270
Valve guide bushing cleaning
With a brush for guides and solvent, clean all the
valve guides.
Head cracking check
With a penetrating liquid, check if there are any
cracks in the combustion chamber, inlet and ex-
haust ducts and on the head surface.
Replace the head if there are cracks.
Valves
Valve check and rectification
1. Visually check if the valve stem has signs of
seizure or damage.
2. Visually check if the valve head shows signs of
overheating or damage. If there are traces of over-
heating or damage, replace valve A. If the un-
evenness of the contact surface can be restored,
rectify the contact surface of the valve seat.
EN - 271
3. Rectify the valve only as much as to obtain an
even surface contacting the valve seat.
MAKE SURE THAT VALVES ARE MACHINED WITH THE
CORRECT ANGLE.
Characteristic
Valve rectification angle:
45.5
4. Visually check if the valve stem end has traces
of abnormal wear.
If the valve stem shows abnormal wear, proceed
with the relevant rectification.
This reworking must however be comprised within
a 2 mm limit from the rated length value.
DO NOT OVERHEAT THE VALVE DURING RECTIFICA-
TION.
Characteristic
Inlet valve rated length:
112.8 mm
Exhaust valve rated length:
114.5 mm
5. Check the valve head thickness.
If the valve head thickness is shorter than the min-
imum value allowed, replace the valve.
Characteristic
Inlet valve minimum thickness allowed:
0.8 mm
Exhaust valve minimum thickness allowed:
1.0 mm
EN - 272
Checking clearance between the valve guide
and the valve stem
1. Ream the valve guide bushing to remove any
burrs.
THIS REAMING MUST BE CARRIED OUT ONLY TO RE-
MOVE ANY BURRS.
2. With a plug gauge, measure the valve guide in-
side diameter at six points. Record the values
measured.
3. With a micrometer, measure the valve stem diameter at six points.
Record the values measured.
4. Clearance calculation
Calculate clearance of each single valve according to the following formula.
Guide inside diameter -
Valve stem outside diameter =
Coupling clearance
Characteristic
Inlet valve Clearance specification values:
0.020 - 0.055 mm
Exhaust valve Clearance specification values:
0.025 - 0.060 mm
Inlet valve allowed limits:
0.080 mm
Exhaust valve allowed limits:
0.090 mm
EN - 273
If clearance values calculated exceed the values
allowed, replace the valve guide and valve.
Valve springs
Valve spring check
1. Check the valve spring obliquity, with a carpen-
ter's square.
Characteristic
Valve spring maximum out of square
<1.6 mm
KEY:
B =Lower than 1.6 mm
If the inclination exceeds the maximum limit, replace the valve spring.
2. With the special tool measure the unloaded length and tension of the valve spring.
Characteristic
Valve spring minimum unloaded length (marked in PINK)
43.9 mm
Valve spring minimum unloaded length (marked in ORANGE)
46.1 mm
Valve spring preloading (marked in PINK)
244.9 N to 38.0 mm (Standard fitting height)
Valve spring preloading (marked in ORANGE)
208.9 N to 38.0 mm (Standard fitting height)
EN - 274
If the minimum unloaded length value and/or the
minimum tension value is below the minimum limit,
replace the valve spring. Reference:
Characteristic
Valve spring unloaded length (marked in PINK)
45.2 0.5 mm
Valve spring unloaded length (marked in OR-
ANGE)
47.4 mm
3. Check that the valve spring supporting surface
is even.
a. Load 49 N to the valve spring.
b. Fit a thickness gauge at point "A", indicated by
the arrow in the figure.
The thickness gauge must measure 0.07 mm
thickness and 12.5 mm length.
Make sure that the thickness gauge does not
reach the spiral centre.
If the thickness gauge reaches the spiral centre,
replace the spring.
Valve guides and seats
Check
Check that the valve spring cap seats and cap
locks are not cracked or worn. Replace the defec-
tive parts, if necessary.
Valve guide replacement
THE REMOVAL AND FITTING OF THE VALVE GUIDE MUST BE PERFORMED WITH A HEAD-
CYLINDER TEMPERATURE EQUIVALENT TO 80C - 100C, AFTER HEATING IT GRADUALLY.
EN - 275
Inlet valve guide
If the valve guide is already fitted with a stop ring
A (the original guide does not have a ring), replace
the head.
1. Take out the valve guide by pushing from the
combustion chamber seat with the following spe-
cial tool.
BE CAREFUL NOT TO DAMAGE THE HEAD
Specific tooling
020387y Punch for valve extraction
2. Insert a new valve guide bushing, until the circlip
is not stopped by the cylinder head.
BE CAREFUL NOT TO CAUSE AN EXCESSIVE
IMPACT DURING FITTING. FAILURE TO OB-
SERVE THIS PRECAUTION CAN CAUSE THE
VALVE GUIDE BUSHING CRACKING.
DO NOT FORCE THE VALVE GUIDE EXCES-
SIVELY SO AS NOT TO TAKE OUT THE STOP
RING.
Specific tooling
020387y Punch for valve extraction
3. Ream the valve guide bushing to remove any
burrs.
THIS REAMING MUST BE CARRIED OUT ONLY TO RE-
MOVE ANY BURRS.
EN - 276
4. Clearance check
Make sure that clearance complies with specifica-
tion values.
Characteristic
Inlet:
0.020 - 0.055 mm
Outlet:
0.025 - 0.060 mm
Valve seats and guides
Checking and cleaning the valve seats
1. Rectify the valve seat, with a mill at 45. Only
remove the quantity of material useful to clean the
seat.
2. Apply a thin layer of minium onto the valve seat.
3. Let the valve fall in its seat, by its own weight,
two or three times.
KEY:
A =Intake
4. Remove the valve.
5. Check the sealing and relevant valve seat as
follows.
Make sure that contact between the
valve and the sealing is continuous on
the whole circumference. Otherwise,
replace the valve.
Make sure that contact between the
valve and its seat is continuous on the
whole circumference. Otherwise, re-
work the valve seat.
Measure the length of the valve seat contact surface.
Characteristic
Valve seat contact surface:
1.2 - 1.6 mm
EN - 277
Otherwise, rework the valve seat.
KEY:
B =Contact surface at the centre of the valve
C =Contact surface length
Valve seat rectification
1. Rectification for inlet valve seats
With a mill at 45, remove the surface
unevenness of the area making con-
tact with the valve seat, only as much
as to obtain an even surface.
KEY:
A =Intake
With a mill at 30, rework the valve seat
so that the largest diameter of the ma-
chining operation at 45, is 29 0.1
mm.
KEY:
B =Inlet seat
With a mill at 70, work the seat so that,
the length of the surface machined with
the mill at 45, turns equal to 1.4 mm.
With the mill at 45, remove any burrs
which are produced during previous
machining operations with mills at 30
and 70.
EN - 278
KEY:
C =Intake
2. Rectification of exhaust valve seats
With a mill at 45, remove the surface
roughness of the area making contact
with the valve seat, only as much as to
obtain an even surface.
KEY:
A =Intake
so that the largest diameter of the ma-
chining operation at 45, is 25 mm.
KEY:
D =Exhaust
so that, the length of the surface ma-
chined with the mill at 45, turns equal
to 1.4 mm.
With the mill at 45, remove any burrs
which are produced during previous
machining operations with mills at 20
and 70.
EN - 279
KEY:
E =Exhaust
Valve manual grinding
1. Grind valves and valve seats manually, with a lapping compound.
2. Once grinding has finished, clean the valves and valve seats.
N.B.
BE CAREFUL NOT TO PUT THE LAPPING COMPOUND IN THE VALVE GUIDES.
Fitting new valves
When the valve seats are reworked, fit the new valves.
Measure the distance between the cylinder head attachment surface (head-cylinder gasket position
surface) and the upper part of the valve.
Make sure that this distance does not exceed the following maximum limits.
Characteristic
Inlet valve maximum limit:
2.775 mm
Exhaust valve maximum limit:
6.026 mm
If the value is higher than the maximum limit al-
lowed, replace the head.
Montaggio testa
HEAD FITTING
N.B.
EN - 280
- CLEAN CAREFULLY ALL THE PARTS TO BE FITTED .
- BEFORE FITTING THE DIFFERENT PARTS, APPLY A LAYER OF ENGINE OIL ONTO ALL THE
SLIDING OR ROTATION SURFACES.
- REPLACE ALL THE GASKETS AND SEALING RINGS.
Head fitting
Initial operations
Using a new head, take into account that the spark plug jackets and coolant outlet union are supplied
separately. Fit these parts following the procedure described below.
1. Wash the head using solvent and dry it with compressed air.
2. Apply a thin layer of special adhesive onto the
jacket surfaces making contact with the head.
Three Bond 1377B Adhesive sealing com-
pound
-
3. With wooden wedges placed on the upper part
of the spark plug jacket, place the spark plug jacket
in the head so that the distance between the spark
plug tightening surface and the upper end of the
jacket is 139 mm.
NOTE:
- DO NOT PLACE THE SPARK PLUG JACKET TOO DEEP-
LY.
- BE CAREFUL NOT TO DAMAGE THE UPPER END OF THE
SPARK PLUG JACKET.
- WHEN INSERTING THE SPARK PLUG JACKET IN THE
SEAT, MAKE SURE THAT IT IS NOT BENT.
EN - 281
4. Apply a thin layer of sealant onto the outlet union
contact section from the head to the throttle body.
5. Drive the union with a wooden wedge and a
hammer. Place the union so that the pipe is in an
orthogonal position with respect to the head sur-
face.
6. Once these operations have finished, remove
each protruding adhesive residue, any wood
splinters etc.
Fitting the valve spring seats on the head
Fit the valve spring seats on the head.
EN - 282
Valve sealing ring fitting
1. Apply engine oil onto the sealing ring hole.
2. Fit the sealing ring manually on the valve guide.
N.B.
- WHEN THE SEALING RING IS FITTED, MAKE SURE THAT
IT DOES NOT BEND.
- DO NOT REUSE ANY RING THAT WAS PREVIOUSLY
BENT OR FITTED INCORRECTLY.
- DO NOT TOUCH THE SEALING LIP OF THE RING.
3. Turn the sealing ring slowly by hand to see if it
is fitted properly.
- NEVER TURN THE SEALING RINGS MORE THAN ONCE,
BECAUSE AN EXCESSIVE ROTATION CAN CAUSE SCOR-
ING FORMATION ON THE SEALING EDGE.
- IF THE SEALING RING CAN NOT TURN FREELY IN ITS
SEAT, IT MEANS THAT IT WAS BENT, INSERTED DIAGO-
NALLY OR WAS INADEQUATELY FORCED.
- DO NOT REUSE ANY RING THAT WAS PREVIOUSLY
BENT OR INSERTED INCORRECTLY.
Valve fitting
Apply oil onto the valve stem. Fit the valve in the guide.
N.B.
- PAY ATTENTION TO THE FITTING POSITION. DO NOT TAKE THE VALVE OUT ONCE IT HAS
BEEN FITTED.
- IF A VALVE THAT IS ALREADY FITTED MUST BE TAKEN OUT, THE SEALING RING MUST BE
REPLACED AGAIN.
Valve identification
- THERE IS AN INDICATION AT THE CENTRE OF THE
VALVE.
Characteristic
HC-ES engine
identification number (4)
EN - 283
Fitting the valve springs, caps and cotters.
1. Fit the valve spring so that the painted side (side
with a longer pitch) is on the cotter part.
2. Fit the cap on the spring. Fit the cotters while
the spring is compressed with the following special
tool:
Specific tooling
3. After fitting the cotters, slightly hit the stem with
a hammer, to make sure that the valve cotters are
fitted firmly.
WARNING
- DURING THIS OPERATION, BE CAREFUL THAT COT-
TERS DO NOT JUMP OUT.
- DURING THIS OPERATION, PROTECT EYES WITH PRO-
TECTIVE GOGGLES.
Head fitting
Next operations
1. Clean and dry the seats threaded on the block.
2. Clean the block upper surface.
- DURING THIS OPERATION, PROTECT EYES WITH PRO-
TECTIVE GOGGLES.
EN - 284
3. Fit the head gasket A, on the centring dowels
inserted in the block.
4. Take the crankshaft to the top dead centre of
cylinders 1-4.
5. Clean the threaded part of the water tempera-
ture sensor.
6. Wrap sealing tape around the threaded part and
fit the sensor in the head-cylinders.
- THE NEW TEMPERATURE SENSOR IS COVERED WITH
A SEALANT LAYER.
THEREFORE, WHEN A SENSOR IS REPLACED, REMOVE
THE SEALANT LAYER BEFORE WRAPPING THE SEAL-
ING TAPE. BESIDES, MAKE SURE THAT THE HOLE OF
THE HEAD THREADED SECTION IS CLEAN.
- THE ORIGINAL SEALANT IS REMOVED BECAUSE AF-
TER BEING STORED FOR A LONG TIME IT HAS LOST ITS
CHARACTERISTICS.
Cylinder head - Water temperature sensor 24.5
34.3
7. Cover each head fixing screw with a thin layer
of engine oil and let it drip.
Fit the head on the block.
N.B.
- BEFORE FITTING THE HEAD, CHECK THE BLOCK.
EN - 285
8. Tighten the screws evenly in two or three
stages, according to the sequence shown in the
figure.
N.B.
- FAILURE TO OBSERVE THE SEQUENCE SHOWN TO
TIGHTEN THE SCREWS, CAN CAUSE CRACKS AND DIS-
TORTIONS ON THE HEAD, LEADING ALSO TO THE EN-
GINE SEIZURE.
- MAKE SURE THAT ALL THE SCREWS ARE TIGHTENED
EVENLY TO THE PRESCRIBED TORQUE.
Camshaft and rocking lever pin fitting
1. Wash and dry holes for screws fixing camshaft
supports.
- WHEN COMPRESSED AIR IS USED, PROTECT EYES
WITH PROTECTIVE GOGGLES.
2. Apply engine oil onto the shaft supports.
- BE CAREFUL NOT TO APPLY OIL INTO THE THREADED
HOLES.
3. Fit the camshaft on the head so that the cam-
shaft pulley positioning pin is in the upper part.
EN - 286
4. Apply sealant onto the support No.1 of the cam-
shaft, at the points shown in the figure.
5. Apply oil onto the camshaft support section.
N.B.
- BE CAREFUL NOT TO APPLY OIL INTO THE THREADED
HOLES WHERE SCREWS FOR SUPPORTS ARE FITTED.
Three Bond 1104 Liquid sealant
-
6. Fit the camshaft supports according to the nu-
merical sequence indicated on them.
N.B.
- BEFORE FITTING THE CAMSHAFT SUPPORTS, CLEAN
EACH SEALANT TRACE FROM SUPPORT No. 1 OF THE
CAMSHAFT.
7. Fit the rocking levers and elastic inserts on the
relevant pins.
Lubricate the parts.
N.B.
- THE INTAKE SIDE PIN CAN BE RECOGNISED BY THE
MILLING LOCATED IN CORRESPONDENCE WITH THE
SPARK PLUG JACKETS.
- PINS MUST BE PLACED WITH THE BIG CHAMFER FAC-
ING TOWARDS THE TIMING SYSTEM SIDE.
8. Fit the pin with the rocking levers on the cam-
shaft supports.
N.B.
- FOR AN EASIER FITTING, IT IS RECOMMENDED TO
KEEP THE ROCKING LEVERS ORIENTED TOWARDS THE
TIMING SHAFT UNTIL THE PIN IS IN THE SEAT ON THE
SUPPORTS.
EN - 287
Head fitting
Final operations
1. Place two spacers between the rocking levers
for inlet valves on the rocking lever pin.
2. Apply engine oil onto the protruding part of the
camshaft T oil seal.
3. Place the oil seal in the right position, with the
special tool recommended.
CAUTION
- BE CAREFUL NOT TO REST THE OIL SEAL ON THE CAM-
SHAFT OIL SEAL ATTACHMENT HOLE.
Specific tooling
020381Y PUNCH TO FIT THE CAMSHAFT OIL
SEAL
4. Fit the pulley for the camshaft toothed belt .
5. Adjust valve clearance and ignition timing.
6. Fit the cylinder head cover with gasket A and
tighten the fixing bolts evenly in two or three
stages, according to the sequence indicated in the
figure.
7. Connect the connector to the engine coolant
temperature sensor.
8. Fit the ignition coil on the cylinder head cover
and tighten it.
9. Fit the exhaust manifold.
10. Fit the inlet manifold.
Pagina Manuale VTL
EN - 288
Exhaust pipe
Base - pistons - cylinders
BLOCK COMPONENTS
A =Vehicle front side * =Non-reusable parts
1. Timing belt cover No.1
2. Timing belt cover No.2
3. Water pump
4. Water pump gasket
5. Dust guard
6. Oil pump
7. Sealing ring
8. Head gasket
9. Cylinder block
10. Crankshaft
11. Flange
12. Timing pinion
13. Main bushings
14. Piston-Pin
15. Piston circlips
16. Connecting rod
17. Connecting rod bushings
EN - 289
18. Oil pump
19. Pipes with pre-filter
20. Rear plate
21. Flange for sealing ring
22. Sealing ring
23. Shoulder rings.
Smontaggio
Block removal
Operations on components
Place the engine on proper engine bench.
Remove the toothed belt
Cylinder head cover removal.
1. Remove the ignition coil unit.
2. Remove the bolts fixing the cylinder head cover.
3. Remove the cylinder head cover.
4.Loosen bolts fixing the cylinder head evenly in
two or three stages, according to the sequence in-
dicated in the figure on the right.
N.B.
- FAILURE TO OBSERVE THE SEQUENCE SHOWN TO
TIGHTEN THE SCREWS, CAN CAUSE CRACKS AND DIS-
TORTIONS ON THE HEAD, LEADING ALSO TO THE EN-
GINE SEIZURE.
- MAKE SURE THAT ALL THE SCREWS ARE TIGHTENED
EVENLY TO THE PRESCRIBED TORQUE.
EN - 290
5. Remove the cylinder head bolts.
6. Remove the cylinder head from the cylinder
block.
7. Remove the head gasket.
8. Remove each gasket residue from the head and
cylinder block surface, with a suitable scraper.
Cylinder block removal - Phase 1
1. Remove the oil pressure switch and oil filter.
2. Remove the crankshaft pulley screw.
N.B.
- AVOID THE CROWN GEAR ROTATION USING THE SPE-
CIAL TOOL.
Specific tooling
EN - 291
- IF THE CRANKSHAFT PULLEY CAN NOT BE TAKEN OUT
MANUALLY, FIT THE FOLLOWING SPECIAL TOOL:
Specific tooling
020380Y TIMING PINION EXTRACTOR
4. Remove the crankshaft pulley flange.
EN - 292
5. Remove the tensioner and relevant spring.
6. Remove the water pump.
7. Remove the water pump gasket.
1. Remove the alternator support bracket, the en-
gine right support with the guide for the oil dipstick.
2. Remove the thermostat cover and thermostat.
3. Remove the water hose.
EN - 293
4. Remove the pressure plate and clutch disc.
N.B.
- AVOID THE FLYWHEEL ROTATION, USING THE FOL-
LOWING SPECIAL TOOL:
Specific tooling
5. Check the flywheel eccentricity.
N.B.
- IF THE FLYWHEEL ECCENTRICITY DOES NOT COMPLY
WITH THE SPECIFICATION REQUIREMENTS, REPLACE
THE FLYWHEEL.
- BEFORE REPLACING THE FLYWHEEL, CHECK THE
LOCKING TORQUE.
Characteristic
Limit value:
0.1 mm
6. Loosen the flywheel fixing screws in the se-
quence indicated in the figure. Remove the fly-
wheel.
- AVOID THAT THE FLYWHEEL TURNS, WITH THE FOL-
LOWING SPECIAL TOOL
Specific tooling
Remove the rear plate.
EN - 294
Oil sump removal
1 Loosen the screws and nuts fixing the oil sump,
operating in two or three stages. Take out bolts
and nuts.
2 Separate the oil sump from the cylinder block
with the following special tool:
Specific tooling
020403Y FLYWHEEL LOCK WRENCH
3. Remove the two oil sump gaskets.
4. Remove the rear flange with the sealing ring.
EN - 295
5. Remove the oil inlet duct with the four nuts and
spacer.
6. Remove the oil pump.
Piston removal
1. Remove the carbon deposits at the end of cyl-
inders.
2. Turn the crankshaft until the piston reaches the
bottom dead centre.
3. Loosen the connecting rod cap nuts, operating
in two or three stages to guarantee torque uni-
formity. Remove then the connecting rod cap.
EN - 296
4. Fit the plastic caps on each connecting rod
screw to protect the thread.
5. Take out the piston, with the connecting rod and
upper bushing, from the upper part of the cylinder
block.
- POSITION THE PISTONS REMOVED AND CONNECTING
RODS, SO THAT THE SINGLE FITTING POSITIONS ARE
EASILY IDENTIFIED.
- BE CAREFUL NOT TO DAMAGE THE BUSHINGS.
Remove the flywheel.
- LOCK THE CROWN GEAR ROTATION BY MEANS OF THE
SPECIAL TOOL.
Specific tooling
EN - 297
Removing the oil sump
OIL SUMP TEST
Visually check the oil sump to detect possible dam-
age or cracks. Replace the oil sump, if necessary.
Pistone
Piston - Removal and inspection
Piston and connecting rod test
Coupling check between the piston and the pin
Turn the piston around the pin axle. If the move-
ment turns hard, replace the piston and pin.
- IF THE PISTON MOVES REGULARLY, WITHOUT JAM-
MING, THIS PISTON COUPLING IS CONSIDERED NOR-
MAL.
Reference:
Check clearance between the piston and the pin
is as specified.
Clearance measurement between the piston
and the pin
- Clearance can be measured following the proce-
dure below.
1.Clearance measurement with the piston and
connecting rod assembled: place the connecting
rod between two V blocks resting on a reference
surface. Measure clearance trying to move the
piston, as indicated in the figure.
- THIS COUPLING CLEARANCE CAN NOT BE MANUALLY
DETECTED.
Characteristic
Piston/pin clearance
EN - 298
0.005 - 0.011 mm
2. Checking piston clearance with the pin after re-
moval:
1. measure the diameter in positions A and B,
shown in the figure. The minimum size found
is the pin seat diameter.
Characteristic
Specification values
19.002 - 19.005 mm
3 Measure the pin diameter in positions A and B,
shown in the figure. The maximum size found is
the pin outside diameter.
The values indicated in the figure are in millime-
tres.
Characteristic
Specification values
18.994 - 18.997
Piston and connecting rod removal
Use the following special tools to carry out removal
operations.
1. Fit the connecting rod in the special tool, as
- THE PISTON AND PIN, AS REGARDS ITS CLEARANCE,
ARE CONSIDERED A SINGLE KIT. THEREFORE, WHEN
REMOVING THE PISTON, BE CAREFUL THAT THE PISTON
AND PIN ARE NOT MIXED UP WITH OTHERS.
- REMOVE THE PISTON ONLY WHEN NECESSARY DUE
TO MALFUNCTIONS.
FAILURE TO OBSERVE THIS RECOMMENDATIONS CAN
LEAD TO A DISASSEMBLY OF THE CORRECT COUPLING
BETWEEN THE CONNECTING ROD AND THE PIN, CAUS-
ING DAMAGE TO THE ENGINE.
Specific tooling
020385Y SUPPORT FOR PISTONS
020386Y TOOL TO FIT/REMOVE THE PISTON
FROM THE CONNECTING ROD
EN - 299
2. Fit the special tool in pin hole.
Take out the pin with a hydraulic press.
- DISASSEMBLE THE SPECIAL TOOL AND USE ONLY THE
CYLINDRICAL PART.
Piston inspection
1. Piston cleaning
Remove the piston rings.
Remove the carbon deposits from the
upper part of the pistons, with a scra-
per.
Clean the slots for the piston rings with
a portion of the sealing ring.
- BE CAREFUL NOT TO SCORE THE SLOTS FOR THE PIS-
TON RINGS.
2. Piston check
Visually check the piston to detect any cracks,
damage or seizures. Replace the piston, if neces-
sary.
3. Piston diameter measurement
Measure the outside diameter at the
point specified, and in a perpendicular
position to the pin.
If the piston ring opening exceeds the allowed limit,
the whole kit must be replaced.
Characteristic
Point H of measurement:
15 mm
Calculate the cylinder piston coupling.
Deduct the piston diameter from the cylinder diameter.
Make sure that clearance between the piston and the cylinder is below 0.045 mm.
If the cylinder piston clearance exceeds the lower limit, carry out the reaming and smoothing operations
of the cylinders, so that the cylinder diameter couples with the oversized piston.
EN - 300
4. Checking coupling clearance between the
piston rings and the piston
Measure the clearances of the piston rings No. 1
and No. 2 on the whole circumference of each slot,
with a thickness gauge.
The maximum value measured is considered to be
the piston ring clearance.
If clearance of the piston ring with the piston ex-
ceeds the limit allowed, measure the piston ring
thickness. Making reference to the following
standard thickness levels. Replace the piston ring
and/or the piston, so that clearance is within the
allowed limits.
Characteristic
Piston - cylinder clearance
Specification values: 0.025 - 0.045 mm
Admissible limit: 0.11 mm
PISTON RING CLEARANCE
Piston ring No. 1 Specification value: 0.03-0.07 mm
Piston ring No. 2 Specification value: 0.02-0.06 mm
Clearance limit allowed 0.12 mm
5. Opening check of the piston ring in the cyl-
inder
Apply oil onto the cylinder walls.
Fit the piston ring in the cylinder.
With the piston, take the piston ring
B to 110 mm from the cylinder block
upper surface.
Measure the piston ring opening, with
thickness gauge, or a feeler gauge.
- IN CASE OF REPLACEMENT, REPLACE THE WHOLE
PISTON RING KIT.
EN - 301
PISTON RING RATED THICKNESS
Piston ring No. 1 1.17-1.19
Piston ring No. 2 1.47- 1.49
PISTON RING OPENING
Piston ring No. 1 ("T" reference mark) 0.27-0.37 mm
Piston ring No. 1 ("N" reference mark) 0.27-0.40 mm
Piston ring No. 1 (clearance limit allowed) 0.12 mm
Piston ring No. 2 0.4-0.55
Piston ring No. 2 (clearance limit allowed) 0.8 mm
Scraper ring (Spring A) 0.2-0.6 mm
Scraper ring (Spring B) 0.15-0.6 mm
Scraper ring (allowed limit) 1.0 mm
Oil scraper piston circlip
(A) = Shape A
(B) = Shape B
Piston rings - Inspection
Piston ring removal
1. Remove the circlips No.1 and No. 2, with an ex-
pander for circlips.
2. Remove the oil scraper rings manually.
3. Remove the oil scraper spring manually.
- POSITION THE PISTON RINGS REMOVED FROM THE
PISTONS SO THAT ITS FITTING POSITION CAN BE EASI-
LY RECOGNISED.
- DO NOT EXTEND THE PISTON RING MORE THAN RE-
QUIRED PURPOSELESSLY.
EN - 302
Piston refitting
Piston and connecting rod fitting
Use the following special tools to carry out fitting
operations.
1. Fit pin B on the special tool, as shown in the
figure:
A=Milled part
Specific tooling
020385Y SUPPORT FOR PISTONS
020386Y TOOL TO FIT/REMOVE THE PISTON
FROM THE CONNECTING ROD
2. Fit the piston and connecting rod on the special
tool, as shown in the figure. Fit the special tool in
the piston where the pin is fitted.
3. Fit the pin in the connecting rod, with a hydraulic
press.
- THE PISTON AND CONNECTING ROD MUST BE FITTED
SO THAT THE PISTON FRONT PART AND THE CONNECT-
ING ROD FRONT PART, BOTH HAVING THE IDENTIFICA-
TION REFERENCE, ARE IN THE SAME DIRECTION.
- THE SPECIAL TOOL MUST BE INSERTED FROM THE
SIDE THAT IS MILLED.
4. Remove the piston-connecting rod assembly
from the special tool.
Remove the special tool from the pin.
EN - 303
Connecting rod
Connecting rod check
1. Visually check the connecting rod, to find pos-
sible damage or cracks.
2. Resorting to a special tool to align connecting
rods, check if connecting rods are bent A or twis-
ted B.
If the bending and/or torsion level exceeds the
maximum allowed value, replace the connecting
rod.
Characteristic
Maximum bending:
0.05 mm
Maximum torsion:
0.05 mm
Pin-connecting rod forced coupling check
1. Measure the pin outside diameter which must
be coupled with the connecting rod, using a mi-
crometer.
2. Measure the inside connecting rod diameter,
with a dial gauge for holes.
3. Determine the forced coupling deducting the
connecting rod inside diameter value from the pin
outside diameter value.
If the forced coupling does not comply with the
specified values, replace the connecting rod.
Characteristic
Forced coupling:
0.015 - 0.044 mm (interference)
EN - 304
Connecting rod clearance measurement.
Measure the axial clearance between the connect-
ing rod and the crankshaft, with a thickness gauge.
If clearance exceeds the specified value, replace
the connecting rod or crankshaft, or both, if nec-
essary.
Characteristic
Axial clearance
Standard: 0.15 - 0.4 mm
Maximum: 0.45 mm
Connecting rod head width in the thrust direc-
tion
21.80 - 21.85 mm
Seat width on the connecting rod pin
22.0 - 22.2 mm
Coupling clearance measurement between the
connecting rod bushings and crankshaft
1. Temporarily fit the flywheel.
EN - 305
2. Clean the coupling area between the connecting
rod cap and the connecting rod.
Draw a mark on one side, so that the part can be
properly refitted, also mark the coupling to the cyl-
inder.
3. Turn the crankshaft until the connecting rod cap
is on the oil sump part.
4. Loosen the nuts of the connecting rod cap even-
ly, operating in two or three stages. Then remove
the nuts of connecting rod cap.
5. Remove the connecting rod cap.
- REPLACE THE CRANKSHAFT, IF THE CONNECTING
ROD PIN HAS SEIZURES.
6. Place a "plastigauge" on the connecting rod pin.
N.B.
- CLEAN ANY OIL TRACES FROM THE CONNECTING ROD
PIN.
EN - 306
7. Fit the connecting rod, making sure that the
coupling marks are aligned. Tighten the connect-
ing rod nuts, operating in two or three stages to
guarantee that they are tightened evenly to the
specified torque value.
- LUBRICATE THE NUTS BEFORE FITTING.
8. Loosen the connecting rod cap nuts, operating
in two or three stages to guarantee torque uni-
formity. then remove the connecting rod bearing
cap.
9. Measure the "plastigauge" thickness at its max-
imum point.
Characteristic
Clearance
0.020 0.044 mm
If clearance does not comply with the specification value, measure the connecting rod pin diameter and
select a bushing with a suitable thickness, or replace the crankshaft.
10. Remove the "plastigauge" from the connecting rod pin.
11. Measure coupling clearances of the bushings of other connecting rods.
Connecting rod bearing thickness selection.
1. Read the classification number of the connecting rod head diameter.
- REPLACE THE BEARINGS WHEN ALL THE INSPECTIONS ARE FINISHED. THE CONNECTING
ROD CAN BE CLASSIFIED IN THREE CATEGORIES: 4, 5, 6.
EN - 307
A =Connecting rod diameter classification
B =Front reference
2. Measure the connecting rod pin diameter.
The measurement must be carried out on 4 points
distanced 90 one from the other, for each con-
necting rod pin, at the points shown in the figure.
The maximum value is considered to be the meas-
urement of the connecting rod pin diameter. Nev-
ertheless, if the variation among the different
diameters measured on the pin exceeds 0.044
mm, replace the crankshaft.
3. Select the connecting rod bushing thickness or replace the crankshaft, according to the results of
points 1 and 2.
The values indicated in the figure are in millimetres.
CONNECTING ROD HEAD TYPES
Name Description Dimensions Initials Quantity
Category 5 50.000 - 49.995 1
Category 5 49.994 - 49.989 2
Category 5 49.998 - 49.983 3
Category 5 49.982 - 49.976 4
Category 5 49.975 or less -
Category 6 50.000 - 49.995 2
Category 6 49.994 - 49.989 3
Category 6 49.998 - 49.983 4
Category 6 49.982 - 49.976 5
Category 7 50.000 - 49.995 3
Category 7 49.994 - 49.989 4
Category 7 49.998 - 49.983 5
Category 7 49.982 - 49.976 6
Category 8 50.000 - 49.995 4
Category 8 49.994 - 49.989 5
Category 8 49.998 - 49.983 6
Category 8 49.982 - 49.976 7
EN - 308
Connecting rod replacement
Wash connecting rods using solvent.
Connecting rod bushing selection
1. Read the category of the connecting rod.
- BE CAREFUL TO PROTECT EYES WITH PROTECTIVE
GOGGLES.
2. Measure the diameter of each connecting rod
pin in four directions, distanced 90 one from the
other, at the points indicated in the figure.
The values indicated are in millimetres.
- THE LARGER VALUE MEASURED DEFINES THE CON-
NECTING ROD PIN DIAMETER. NEVERTHELESS, IF THE
DIFFERENCE AMONG ALL THE VALUES MEASURED EX-
CEEDS 0.044 MM, REPLACE THE CRANKSHAFT.
3. Select the connecting rod bushings according the following table.
Category 5 50.000 - 49.995 1
Category 5 49.994 - 49.989 2
Category 5 49.998 - 49.983 3
Category 5 49.982 - 49.976 4
Category 6 50.000 - 49.995 2
Category 6 49.994 - 49.989 3
Category 6 49.998 - 49.983 4
Category 6 49.982 - 49.976 5
Category 7 50.000 - 49.995 3
Category 7 49.994 - 49.989 4
Category 7 49.998 - 49.983 5
Category 7 49.982 - 49.976 6
Category 8 50.000 - 49.995 4
Category 8 49.994 - 49.989 5
Category 8 49.998 - 49.983 6
Category 8 49.982 - 49.976 7
EN - 309
Cylinders
Cylinder block test
1. Removing gasket residues.
Remove all gasket residues from the cylinder
block.
2. Cylinder block cleaning
Clean the cylinder block using a soft brush and
solvent.
3. Cylinder block upper surface check.
Check for any deformation of the head gasket con-
tact surface, using a precision scale and a thick-
ness gauge.
If unevenness exceeds the limit allowed, replace
the cylinder block.
Characteristic
Maximum unevenness:
0.10 mm
4. Cylinder check
Measure the diameter of each cylinder, at six
points a shown in the figure.
Make sure that the difference between the maxi-
mum and the minimum diameter of each cylinder
is within 0.1 mm. If the difference between the
maximum and the minimum value exceeds 0.1
mm, ream and/or grind the cylinder hole.
The grinding angle is 35 5. Surface roughness
is 1 - 4Z.
Reference:
The table indicated below identifies the cylinder
diameter when oversized pistons are used. Meas-
ure the oversized piston diameter. Continue with
the cylinder finishing according to the piston diam-
eter.
Measure the diameter of each cylinder
in the position shown in the figure. The
EN - 310
measured value is considered to be the
cylinder diameter.
Characteristic
Cylinder diameter (standard)
76.000 - 76.030
Cylinder diameter (OS/0.25)
76.250 - 76.280
Cylinder scale removal
If scales are formed in the upper part of the cylin-
der holes, a special reamer is necessary to remove
them.
Cylinder reaming
1. Cylinder diameter measurement
Measure the diameter at a point that is 45 mm
away from the upper surface of the cylinder, in the
direction shown in the figure.
If the measured value exceeds 76.28 mm, replace
the cylinder block.
2. Determining the cylinder finishing diameter
Measure the oversized piston diameter
by means of a micrometer.
N.B.
- THE MEASUREMENT MUST BE CARRIED OUT IN COR-
RESPONDENCE WITH THE INDICATED POINT H = 15 MM.
- CARRY OUT THE MEASUREMENT IN AN ORTHOGONAL
POSITION WITH RESPECT TO THE PIN.
Calculate the cylinder finishing size, as follows:
A: Piston diameter
B: Cylinder piston clearance 0.025 - 0.045 mm
C: Grinding tolerance 0.02 mm
D: Finishing diameter
D =A +B - C
EN - 311
3. Grind the cylinder after the reaming.
Ream the cylinder, leaving a reaming tolerance of 0.02 mm.
Grind the cylinder.
Grinding angle: 35 5
Degree of surface machining: 1 - 4Z
A =Grinding angle
B =Surface machining
Cylinder block replacement
1. Wash the cylinder block using solvent.
2. Insert the shutter on the oil delivery up to a 3.0
1.0 mm depth, measured from the upper surface
of the cylinder.
N.B.
- THE CYLINDER BLOCK IS PROVIDED TOGETHER WITH
THE PISTONS, AS A SINGLE KIT. THEREFORE, BE CARE-
FUL THAT EACH PISTON IS FITTED IN THE RELEVANT
CYLINDER.
N.B.
- TO INSERT THE PARALYSER, USE A 10 MM OUTSIDE
DIAMETER BUFFER.
Category 5 50.000 - 49.995 1
Category 5 49.994 - 49.989 2
Category 5 49.998 - 49.983 3
Category 5 49.982 - 49.976 4
Category 6 50.000 - 49.995 2
Category 6 49.994 - 49.989 3
Category 6 49.998 - 49.983 4
Category 6 49.982 - 49.976 5
Category 7 50.000 - 49.995 3
Category 7 49.994 - 49.989 4
Category 7 49.998 - 49.983 5
Category 7 49.982 - 49.976 6
Category 8 50.000 - 49.995 4
Category 8 49.994 - 49.989 5
Category 8 49.998 - 49.983 6
Category 8 49.982 - 49.976 7
EN - 312
3. Crankshaft bearing selection
Read the category number of the main
bearing.
Measure the main journal diameter at
the points indicated in the figure.
The measurement must be performed in four di-
rections for each support point, distanced 90 one
from the other, as indicated in the figure.
Select the main bushing according to the following table.
Piston selection
1) Read the type of the cylinder coupling.
Key
A =Cylinder type No.1
B =Cylinder type No.2
C =Cylinder type No.3
D =Cylinder type No.4
EN - 313
Select a piston that has the same type
of cylinder coupling E.
N.B.
- THE COUPLING TYPE E IS INDICATED ON THE PISTON
CROWN.
Crankcase bearings
Oil sealing rear gasket replacement
1. Rear sealing ring removal.
Remove the sealing ring from the flange, using a
punch.
N.B.
- BE CAREFUL NOT TO DAMAGE THE SEAT WHERE THE
SEALING RING IS FITTED.
2. Rear sealing ring fitting.
Insert a new ring using in the seat with the follow-
ing special tool.
N.B.
- BE CAREFUL THAT THE RING IS NOT FITTED DIAGO-
NALLY.
- THE SPECIAL TOOL IS DESIGNED TO CARRY OUT THE
INSTALLATION ALSO WHEN THE FLANGE IS FITTED ON
THE ENGINE.
Specific tooling
020383Y Punch for flywheel fitting
Timing side oil sealing ring replacement
1.Sealing ring removal.
Remove the sealing ring from the oil pump, using
a punch.
FITTING.
EN - 314
2.Timing side sealing ring fitting
Insert a new sealing ring using the following spe-
cial tool.
THE SPECIAL TOOL IS DESIGNED CARRY OUT REMOVAL
AND REFIT DIRECTLY ON THE VEHICLE.
Specific tooling
SHAFT OIL SEAL
Crankshaft
Check the axial clearance of the crankshaft.
If the axial clearance exceeds the limit allowed,
measure the thickness of the shim washers with
the block. If the measured value is below 23.59
mm, replace the half rings. If the value measured
exceeds 23.59 mm, replace the crankshaft.
- MEASURE THE AXIAL CLEARANCE WITH A DIAL
GAUGE.
Characteristic
Crankshaft axial clearance
0.02 0.22 mm
Maximum clearance limit allowed: 0.30 mm
Checking coupling clearance of the main
bushing.
1. Loosen the main bearing screws gradually, op-
erating in two or three stages, according to the
sequence indicated in the figure.
Remove the support screws.
EN - 315
2. With the fixing screws remove the main bearing
with the bushing.
- KEEP THE LOWER BUSHING COUPLED WITH THE MAIN
BEARING. POSITION THE MAIN BEARING, IN GOOD OR-
DER.
3. Take out the crankshaft.
- Remove the shoulder rings.
- If main journals or bushings are damaged, re-
place the crankshaft with the bushings or just the
bushings.
4. Clean the main journals and bushings using sol-
vent. Dry them blowing compressed air.
5. Check main journals and bushings for scoring
or porosity.
If the main journals are damaged, replace the
crankshaft. If the main bushings are damaged, re-
place them.
WARNING
- PROTECT EYES WITH PROTECTIVE GOGGLES DURING
THE CLEANING OPERATION.
6. Fit the main bushings on the block and on the
main bearings and keep the original position.
- DO NOT TOUCH THE METAL SURFACE OF BEARINGS.
EN - 316
7. Hold the two crankshaft ends with two V-shaped
blocks.
Measure the crankshaft eccentricity with a dial
gauge.
If the eccentricity exceeds this limit, replace the
crankshaft.
Characteristic
Eccentricity limit allowed:
0.06 mm
8. Place the crankshaft in the cylinder block.
9. Apply a "plastigauge" string onto each crank-
shaft main journal.
10. Fit the main bearings: Tighten the screws
evenly, in the sequence indicated in the figure.
N.B.
- THE MAIN BEARINGS HAVE THE ARROWS WHICH INDI-
CATE THE TIMING SIDE AND ARE NUMBERED FROM 1 TO
5.
- NO. 1 IS THE TIMING SIDE.
EN - 317
11. Remove the main bearings with the bushings.
12. Measure the "plastigauge" thickness at its
maximum point.
If clearance does not comply with the specification
values, measure the diameter of the main journal
area and select the bushings, or replace the crank-
shaft.
13. Remove the "plastigauge" from the main jour-
nals.
Characteristic
Clearance
0.024 0.042 mm
Main bushing category selection.
1. Read the references to recognise the category
of cylinder block main bearings.
N.B.
- REPLACE THE MAIN BUSHINGS AFTER ALL THE IN-
SPECTIONS HAVE BEEN CARRIED OUT.
- TO SELECT THE MAIN BUSHINGS AFTER REPLACING
THE CRANKSHAFT, REFER TO, " CRANKSHAFT RE-
PLACEMENT" .
- THERE ARE FOUR TYPES , IDENTIFIED BY NUMBERS 5,
6, 7 AND 8.
- REFERENCES ARE AS INDICATED IN THE FIGURE.
2. Measure the crankshaft main journals. The measurement must be carried out on 4 points distanced
90 one from the other, for each crankshaft pin, at the points shown in the figure.
The maximum value is considered to be the measurement of the main journal.
Nevertheless, if the variation among the diameters measured on the pin exceeds 0.026 mm, replace
the crankshaft.
The values indicated in the figure are in millimetres.
EN - 318
5 =Main bearing category
3=Main bearing category
3. Select the main bushings or replace the crankshaft, according to the results of points 1 and 2.
- CONNECTING ROD HEAD TYPES -
Category 5 49.995 - 50.000 1
Category 5 49.989 - 49.994 2
Category 5 49.983 - 49.988 3
Category 5 49.976 - 49.982 4
Category 6 49.995 - 50.000 2
Category 6 49.989 - 49.994 3
Category 6 49.983 - 49.988 4
Category 6 49.976 - 49.982 5
Category 7 49.995 - 50.000 3
Category 7 49.989 - 49.994 4
Category 7 49.983 - 49.988 5
Category 7 49.976 - 49.982 6
Category 8 49.995 - 50.000 4
Category 8 49.989 - 49.994 5
Category 8 49.983 - 49.988 6
Category 8 49.976 - 49.982 7
Crankshaft replacement
1. Wash the crankshaft using solvent. Dry it with
compressed air.
2. Crankshaft bushing selection
Read the category of the main bearing.
N.B.
- MAKE SURE THAT THE LUBRICATION DUCTS ARE
FREE.
Main bearing categories
5 =Category of support No.5 (FLYWHEEL SIDE)
4 =Category of support No.4
1 =Category of support No.1 ( TIMING SIDE)
EN - 319
Read the category of the main journal
on the crankshaft.
Main journal categories
5 =categories of the main journal No.5 (FLYWHEEL SIDE)
4 =categories of the main journal No.4
1 =categories of the main journal No.1 (TIMING SIDE)
Set the category of main bushings, us-
ing the table shown below.
M =Crankshaft
N =Main journal category
O =Cylinder block
N =Main bearing category
3. Connecting rod bushing selection
Read the category of the connecting
rod pin.
Connecting rod pin category
1 =Category of the connecting rod pin No.1 (TIMING SIDE)
2 =Category of the connecting rod pin No.2
3 =Category of the connecting rod pin No.3
EN - 320
4 =Category of the connecting rod pin No.4 (FLYWHEEL SIDE)
Read the category of the connecting
rod head.
Connecting rod head categories
U =Front reference
V = Connecting rod category
Set the category of connecting rod
bushings, using the table shown be-
low.
Connecting rod bushing categories
M = Crankshaft
N = Categories of the connecting rod pin
O =Connecting rod
P =Connecting rod categories
Montaggio
Water pump fitting
1. Fit a new water pump gasket on the cylinder
block.
EN - 321
2. Fit and tighten the water pump to the specified
torque value.
N.B.
- WHEN STUD BOLTS ARE LOOSENED OR REPLACED,
APPLY THE RECOMMENDED PRODUCT ONTO THE
THREADED SECTION FROM THE CYLINDER BLOCK
SIDE.
pound
-
Oil filter fitting
1. Apply a reduced quantity of engine oil onto the
oil filter gasket.
2. Screw the oil filter until the gasket makes con-
tact with the oil pump.
3. Then, turn once more the oil filter completely
(360).
EN - 322
pressure switch fitting
1. Clean the threaded part of the pressure switch.
Wrap a sealing tape around the threaded part.
N.B.
- THE NEW PRESSURE SWITCHES ARE COATED WITH
SEALANT. THEREFORE, WHEN THE PRESSURE SWITCH
IS REPLACED WITH A NEW ONE, FIRST, REMOVE THE
COATING COMPLETELY SINCE THE PRODUCT LOOSES
ITS CHARACTERISTICS WITH TIME. ALSO CLEAN THE
THREADED HOLES WHERE THE SWITCH IS FITTED.
2. Tighten the oil pressure switch to the specified
torque value, using a box-spanner.
Spring connection to the timing belt tensioner
Connect the spring to the timing belt tensioner. At-
tach the spring ring on the pin. Fit the belt tensioner
and fit the screw.
Push the tensioner towards the alternator to the
end of the travel position. Temporarily tighten the
tensioner.
Water filler fitting
Fit the water filler.
Cylinders lock for water inlet 5.9 8.8 Nm
EN - 323
Water pipe fitting
Fit the water pipe to the cylinder block to use the
throttle body.
Fit the relevant clamps.
Fitting the clutch disc and driven plate
1. Fit the special tool A in the rear end of the crank-
shaft.
2. Fit the clutch disc.
Specific tooling
3. Fit the clutch cover, aligning the reference pin
of the same cover.
Tighten the fixing bolts to the prescribed torque.
Clutch cover 1522
Flywheel fitting
1. Fit the flywheel on the crankshaft.
2. Application of sealant to the flywheel screws.
Wash the flywheel screws, then, remove grease and dry them.
N.B.
- WHEN GREASE IS REMOVED FROM SCREWS, CLEAN COMPLETELY EVERY TRACE OF OIL,
USING SOLVENT.
- MAKE SURE THAT THERE ARE NO TRACES OF ADHESIVE OR FOREIGN MATTER, (DUST),
ON SCREWS.
- ALSO WHEN USING NEW SCREWS, CARRY OUT THIS OPERATION.
Check for possible damage to the flywheel screws. Replace each damaged flywheel screw.
- CARRY OUT OPERATIONS OF POINT (1) ALSO WHEN A NEW SCREW IS USED.
Clean the threaded seats of the crankshaft. Remove grease and dry them.
- MAKE SURE THAT THERE ARE NO TRACES OF SEALANT OR FOREIGN MATTER, AS FOR
EXAMPLE DUST, IN THE FLYWHEEL THREADS.
EN - 324
- WHEN REMOVING GREASE, CLEAN ANY TRACES OF OIL FROM THE THREADED AREA WITH
A CLOTH SOAKED IN ALCOHOL.
- DO NOT ALLOW THAT RESIN OR RUBBER PARTS MAKE CONTACT WITH ALCOHOL, ESPE-
CIALLY THE SEALING RING.
Clean and remove grease from the flywheel surface.
- WHEN REMOVING GREASE, USE A CLOTH SOAKED IN ALCOHOL.
- DO NOT ALLOW THAT RESIN OR RUBBER PARTS MAKE CONTACT WITH ALCOHOL.
Apply two or three drops of product on-
to the threaded section front end of
each one of the flywheel bolts.
- WARNING: APPLY LUBRICANT ONLY TO THE FIRST
SECTION OF THE THREADED SCREW. AN EXCESSIVE
AMOUNT OF LUBRICANT COULD REACH THE COUPLING
SURFACES. THIS COULD LOOSEN THE BOLTS.
- NEVER USE ANOTHER SEALANT THAN THE RECOM-
MENDED.
- AVOID THAT THE SEALANT REACHES RESIN OR RUB-
BER PARTS.
Three Bond 1324C Sealant
-
3. At the same time tighten the bolts fixing the fly-
wheel to the following torque and in the sequence
indicated in the figure.
4. Tighten the bolts fixing the flywheel to the pre-
scribed torque according to the sequence indica-
ted in the figure.
- USE THE SPECIFIC TOOL TO PREVENT THE CRANK-
SHAFT FROM TURNING WITH RESPECT TO THE CROWN
GEAR.
CAUTION
- WHILE BOLTS ARE TIGHTENED, CHECK THERE IS NO
SEALANT ON THE BOLT SEAT SURFACE. IF THE SEAL-
ANT SEEPS, REPEAT THE OPERATION FROM POINT 2.
Specific tooling
Flywheel fixing screws 44 64 Crankshaft - Fly-
wheel 7898
EN - 325
5. Measure the flywheel eccentricity using the dial
gauge.
- REPLACE THE FLYWHEEL IF ECCENTRICITY EXCEEDS
THE LIMIT ALLOWED.
Characteristic
Maximum limit allowed
0.1 mm
Fitting the flange supporting the flywheel side
sealing ring
1. Apply sealant onto the coupling surface with the
cylinder block, as shown in the figure.
CAUTION
- APPLY THE RIGHT SEALANT QUANTITY IN ORDER TO
AVOID THE FORMATION OF EXCESSIVE RESIDUES IN-
SIDE THE ENGINE.
Three Bond 1207C SEALANT
-
2. Apply engine oil onto the sealing ring internal
surface.
Fit the flange to the cylinder block. Tighten to the
Cylinder block - Rear oil seal ring 69
Cylinder block fitting
1. Make sure that pins are fitted at the front, rear
and upper positions of the cylinder block, accord-
ing to the indications indicated in the figure.
Make sure that the protrusion of each single pin,
complies with the value specified below.
Specific protrusion value
A: 4 0.5 mm
B: 8 1.0 mm
C. 7 1.0 mm
D: 3 1.0 mm
EN - 326
E: 6.5 1.0 mm
F =Front view
R =Rear view
P =Diagram view
If the pins fitted are not rectilinear or the protrusion value does not comply with the specified value,
replace the pin.
Cylinder block fitting
N.B.
- ALL PARTS TO BE REFITTED MUST ALSO BE CLEANED USING SOLVENT (EXCEPT FOR
SOME PARTS, SUCH AS BEARINGS WITH GREASE SEAL, SEALING GASKETS, DUST GUARD
AND ELECTRICAL COMPONENTS).
- THEN DRY THEM, USING COMPRESSED AIR.
WARNING
- WHEN COMPRESSED AIR IS USED, REMEMBER TO PROTECT EYES WITH PROTECTIVE
GOGGLES.
rear plate fitting
Fit the rear plate on the cylinder block with a fixing
screw.
Tighten the screw to the specified torque value.
Cylinder block for clutch rear plate 15 22 Nm
Crankshaft pulley flange fitting
Fit the crankshaft pulley flange so that the input
edge for the belt is positioned towards the oil
pump.
EN - 327
Crankshaft fitting
1. Fit the main bushings on the block and on sup-
ports.
N.B.
- DO NOT TOUCH THE FRONT AND LOWER SURFACES
OF BUSHINGS. MAKE SURE THAT BUSHINGS ARE PER-
FECTLY FITTED.
2. Lubricate the seat of each bushing with engine
oil.
- DO NOT TOUCH THE FRONT AND LOWER SURFACES
OF BUSHINGS. DO NOT APPLY ENGINE OIL ONTO THE
MAIN BEARINGS.
3. Fit the crankshaft in the cylinder block.
4. Apply engine oil onto the shoulder rings.
Fit the shim half rings on support No. 3, make sure
that grooves are facing towards the crankshaft.
EN - 328
5. Apply oil onto the crankshaft main journal.
- AVOID THAT THE OIL FLOWS IN THE THREADS FOR THE
MAIN BEARING SCREWS.
6. Fit the main bearing with the reference arrow
facing towards the oil pump and following the nu-
merical sequence.
7. Apply engine oil, in a reduced quantity, onto the
support screws.
Tighten the screws until the specified torque value,
operating in two or three stages, according to the
sequence indicated in the figure.
Arrangement to fit the head on the engine
1. Place the cylinder block on a stand for engines.
2. Clean and dry the threaded holes for head
screws
N.B.
- MAKE SURE TO WEAR PROTECTIVE GOGGLES EACH
TIME AIR COMPRESSED IS USED.
Specific tooling
020396Y ENGINE SUPPORT ATTACHMENT
3. Align the timing pinion with the oil pump indica-
tor.
EN - 329
4. Place the new head gasket on the cylinder block
positioning reference A.
5. Turn the timing crankshaft, until the pulley ref-
erence mark F is in the highest position.
6. Fit the head from the cylinder block.
7. Apply engine onto the thread of head screws.
8. Fit the screws on the head.
9. Tighten the head screws to rated torque value,
evenly, operating in two or three stages and fol-
lowing the sequence shown in the figure.
N.B.
- BE CAREFUL NEITHER TO DAMAGE THE HEAD, NOR
THE SURFACE WHERE SUCH GASKET IS RESTING.
- NEVER TURN SEPARATELY NEITHER THE CRANK-
SHAFT, NOR THE CAMSHAFT, BEFORE FITTING THE TIM-
ING BELT.
N.B.
- AS REGARDS THE TWO SCREWS THAT ARE ON THE
TIMING SIDE, USE THOSE HAVING A 112 MM RATED
LENGTH.
10. Head-cylinder cover fitting
Check for possible damage dependent
on head cover gaskets. Replace the
head cover gasket, if it is damaged.
Head cover gasket replacement (Only
applicable to cases where this replace-
ment is necessary): remove the gasket
from the head cover and fit the new
EN - 330
gasket so that the identification is loca-
ted on the inlet manifold side.
Check for possible damage on the
spark plug jacket sealing rings. Re-
place the damaged sealing rings.
Fit the cylinder head cover on the cyl-
inder head.
Tighten the bolts fixing the cylinder
head cover to the prescribed torque,
according to the sequence indicated in
the figure on the right.
N.B.
- BE CAREFUL NOT TO DAMAGE THE SPARK PLUG PIPE
SEALING RING DURING FITTING.
Fit and tighten the ignition coils on the
cylinder head cover.
11. Fit the toothed belt.
Crankshaft pinion fitting
Fit the timing belt pinion.
EN - 331
Fitting the timing pinion fixing screw
Fit the timing pinion fixing screw Tighten the screw
- AVOID THE ROTATION OF THE CRANKSHAFT BY USING
THE SPECIAL TOOL BELOW.
Specific tooling
Piston and connecting rod fitting
Temporarily fit the flywheel on the crankshaft.
N.B.
- DO NOT LUBRICATE SCREWS AND THREADED HOLES
OF THE FLYWHEEL.
1. Fit the oil scraper spring in the relevant seat.
Make sure that the end is positioned as in the fig-
ure.
- DO NOT OPEN THE SPRING MORE THAN NECESSARY.
2. Fit the oil scraper upper ring, so that it fits in the spring edge.
- MAKE SURE THAT THE END OF THE RING IS MOVED 90 TO THE RIGHT WITH RESPECT TO
THE SPRING END.
- DO NOT EXTEND THE RING MORE THAN NECESSARY.
- MAKE SURE THAT THE OIL SCRAPER RING CAN BE EASILY TURNED.
EN - 332
3. Insert the lower ring, so that it also fits in the
spring.
- MAKE SURE THAT THE END OF THE RING IS MOVED 90
TO THE RIGHT WITH RESPECT TO THE SPRING END.
- DO NOT EXTEND THE RING MORE THAN NECESSARY.
- MAKE SURE THAT THE OIL SCRAPER RING CAN BE
EASILY TURNED.
4. Using an expander, fit the sealing ring No. 2 with
the reference mark T or N facing upwards.
5. Position the sealing rings so that the end of each
ring reaches the respective points, as indicated in
the figure.
- IT IS NOT NECESSARY TO STRICTLY FOLLOW THE FIG-
URE INDICATIONS. NEVERTHELESS, MAKE SURE THAT
THE END OF THE RING IS ALIGNED WITH THE THRUST
DIRECTION. BESIDES, EACH RING MUST BE DEVIATED
APPROX. 120 /180 FROM THE ADJACENT RING.
6. Fit the bushings on the connecting rods and rel-
evant caps, being careful that the fingers of the
operator do not contact the upper and lower sur-
faces of the bushings.
7. Cut the specific vinyl pipes with a suitable
length. Put the vinyl pipes on each connecting rod
screw.
EN - 333
8. Apply engine oil onto the sealing rings, pins,
connecting rod bushings, to the cylinder walls and
to the connecting rod pins.
9. Compress the sealing rings by means of the
special tool, making sure that the sealing sing ends
do not move during fitting.
10. Push the piston manually into the cylinder. The
arrow must be placed towards the oil pump side.
- BE CAREFUL NOT TO DAMAGE THE BUSHINGS OF THE
CONNECTING ROD DURING FITTING.
- BE CAREFUL NOT TO DAMAGE THE CONNECTING ROD
PINS DURING THE PISTON FITTING.
Specific tooling
020328Y LOCK UP RINGS
11. Push the piston manually until the connecting
rod reaches the connecting rod pin.
12. Apply engine oil onto the bushing of each con-
necting rod cap.
- DO NOT TOUCH THE FRONT SURFACE OF THE BUSH-
INGS.
13. Remove the vinyl pipes, which were put on the
connecting rod screws for protection.
14. Fit the connecting rod caps with the reference
facing towards the oil pump side.
- WITH THE CONNECTING ROD CAP PROPERLY FITTED,
THE BUSHING CLAMPS ARE ON THE SAME SIDE.
EN - 334
15. Apply a small quantity of engine oil onto the
connecting rod locking nuts. Tighten the nuts to the
specified torque value, operating evenly in two or
three stages.
16. For each cylinder, carry out the operations de-
scribed from point 1 to point 16.
17. Remove the flywheel.
18. Remove the special tool.
Specific tooling
Oil pump fitting
1. Apply adhesive onto the coupling surface of the
oil pump with the cylinder block.
2. Replace the O-ring gasket A of the oil pump with
a new one.
-
3. Apply engine oil onto the sealing ring internal
surface.
Fit the oil pump to the cylinder block. Tighten to the
Cylinder block - Oil pump 69
EN - 335
Oil suction system fitting
Fit the oil suction system interposing a new gasket
and spacer.
Lock the nuts.
Nut locking 15 22
Oil sump fitting
1. Apply sealant onto the cylinder block surface.
- APPLY THE RIGHT SEALANT QUANTITY IN ORDER TO
AVOID THE FORMATION OF EXCESSIVE RESIDUES IN-
SIDE THE ENGINE.
-
2. Position the oil sump gaskets.
- MAKE SURE THAT THE FINAL SECTION OF THE OIL
SUMP GASKET OVERLAPS AT LEAST 10 MM WITH AD-
HESIVE.
3. Fit the oil sump
Tighten the screws and nuts fixing the oil sump to the specified torque value evenly and operate in two
or three stages.
Fitting the thermostat in the cylinder block
Fit the thermostat in the cylinder block so that the
wander plug section A can be placed on the upper
side.
- BE CAREFUL TO FIT THE THERMOSTAT WANDER PLUG
IN THE RIGHT DIRECTION. FAILURE TO OBSERVE THIS
SAFETY MEASURE CAN CAUSE OVERHEATING.
EN - 336
Controlli
Checking and adjusting the ignition timing
1. Connect the special tool indicated below to the diagnostic tester connector (DLC) located at the lower
part of the instrument panel.
Specific tooling
020618Y Cable harness for connecting the OBD Connector and the Diagnostic Tester
2. Prepare the diagnosis instrument DS-21.
3. Select "Actuator - Terminal T - Terminal T
ON" from the option list.
4. Connect a probe to the ignition cable harness of
cylinder No.4, then start the engine.
KEY:
A= Probe
B= Ignition coil
5. Check that the reference of the ignition timing
on the flywheel is aligned with the indicator of the
rear bottom plate.
Ignition timing:
Before top dead centre 3 2
CHECKING AND ADJUSTING THE IGNITION TIMING IS
GENERALLY CARRIED OUT WITH THE ENGINE HOT.
6. If the ignition timing reference is not aligned with
the indicator, adjust the timing turning the cam-
shaft sensor.
EN - 337
COMPRESSION CHECK
IF AFTER THE ENGINE TUNE IN, A POWER LOSS, EXCES-
SIVE OIL OR FUEL CONSUMPTION ARE DETECTED,
MEASURE THE CYLINDER COMPRESSION PRESSURE.
1. Heat the engine.
2. Set the ignition switch to OFF.
3. Remove the fuel pump relay from the relevant housing.
4. Remove all the spark plugs from the cylinder head.
5. Fit a cylinder compression gauge in the spark plug hole.
6. Let the engine run and measure the compression value.
PUSH THE ACCELERATOR PEDAL COMPLETELY DURING THE COMPRESSION VAL-
UE MEASUREMENT.
ALWAYS USE A BATTERY COMPLETELY CHARGED SO AS TO OBTAIN A SPEED
EQUAL TO AT LEAST 300 RPM.
Compression value:
1373 kPa (14 kgf/cm2) at 300 rpm
Minimum pressure:
1030 kPa (10.5 kgf/cm2) at 300 rpm
Reading difference among cylinders:
147 kPa (1.5 kgf/cm2) at 300 rpm
If the compression of one or more cylinders is low, add a small quantity of engine oil in the cylinder
through the spark plug hole, then measure the cylinder compression again.
- If by adding oil, the compression has improved, probably the piston rings and/or cylinder holes are
worn or damaged.
- If pressure remains low after carrying out this operation, probably the valves stick or are not placed
properly in their seats, or the head gasket sealing is loose.
EN - 338
Idle speed check and adjustment_
Arrangements to be carried out before the idle
speed adjustment.
- Check and adjust ignition timing.
- Set all the accessory switches to OFF.
1. Connect the special tool 1 to the diagnostic test-
er connector 2 under the instrument panel.
Specific tooling
2. Prepare the diagnosis instrument DS-21.
3. Warm up the engine. Let the engine run at 2500 rpm for about two minutes.
4. Select the option "Current data indication -
Current data monitoring " from the option list.
WHEN THE DIAGNOSIS INSTRUMENT DS-21 IS NOT
USED, CONNECT A RPM INDICATOR TO THE REV. TER-
MINAL USING THE SPECIAL TOOL (SST).
Specific tooling
09991-87402-000 Rpm indicator pulse pickup
wire (Engine speed measurement)
KEY:
1. Special tool
2.Diagnostic tester connector
A REV CONNECTOR
B Ground
5. Measure the idle speed. M/T vehicles: 900 50
rpm
If the number of revolutions at idle speed does not
correspond to the specified value, adjust by means
of the idle speed set screw located on the throttle
body using a key C of 4 mm.
TO REDUCE THE NUMBER OF REVOLUTIONS, TURN THE
IDLE SPEED SET SCREW CLOCKWISE. TO INCREASE,
TURN THE IDLE SPEED SET SCREW ANTICLOCKWISE.
Clutch
Clutch
EN - 339
This section of the manual describes how to inspect, remove and fit clutch components.
Clutch
As regards the main manufacturing principles of the gear and clutch for the new Porter 16V, there are
no changes with respect to the current one. The maintainability and duration level has been kept (op-
erative life) and guaranteed up to now, while an improvement has been introduced to face engine output
power increase due to a change (engine capacity increase) of the engine to be fitted. As a direct result
of engine output power increase, specifications for the clutch and clutch cover have been modified with
respect to those of the current Porter model.
KEY:
1. Diaphragm spring
2. Clutch disc
3. Lever
4. Bearing
5. Bell
Smontaggio - montaggio
Removal
EN - 340
Remove the parts, following the numerical order shown in the figure below.
Components:
1. Spring
2. Thrust bearing hub stop
3. Clutch lever
4. Thrust bearing
5. Lever stop
6. Pressure plate
7.Clutch disc
Installation
Fit the single parts according to the numerical order shown in the figure below.
Components:
EN - 341
1. Clutch lever stop
2. Thrust bearing
3. Thrust bearing hub stop
4. Clutch lever
5. Spring
6. Clutch disc
7. Pressure plate
A= Apply MP grease
B= Apply EP grease
C= Apply EF grease
Fitting the clutch disc and driven plate
1. Fit the special tool A in the rear end of the crank-
shaft.
2. Fit the clutch disc.
Specific tooling
3. Fit the clutch cover, aligning the reference pin
of the same cover.
Tighten the fixing bolts to the prescribed torque.
Clutch cover 1522
4. Apply grease for long duration onto the grooved
section of the clutch disc B.
EN - 342
5. With a thickness gauge and using the special
tool, check the diaphragm spring, to detect possi-
ble height deviations.
Specific tooling
020197y Instrument to measure the height of
the clutch diaphragm spring
Characteristic
Height deviation
Limit: 0.7 mm
6. If height deviation exceeds the specified limit,
adjust the diaphragm spring with the special tool
C.
Specific tooling
020195y Tool kit to align the diaphragm spring
7. Fit the clutch lever.
Apply EP grease onto the thrust bear-
ing hub and to the lever contact sur-
face.
Apply EP grease onto the clutch lever
and to relevant contact surface.
8. Fit the vehicle gear unit.
Revisione
Clutch bell and diaphragm spring
Test the following parts. Replace any defective
part.
1. Check the clutch pressure plate and flywheel
contact surface with the clutch disc; checking that
there are no signs of wear or overheating.
2. Check that there are no signs of wear, corrosion
or damage on the lever.
EN - 343
Clutch lever stop
Check for wear or damage.
Spring
Clutch lever
Clutch disc
1. Check the clutch disc for signs of wear. Rivet
depth
Characteristic
Limit
0.3 mm
2. Check for possible eccentricity of the clutch disc.
Limit:
Characteristic
Longitudinal eccentricity
1.0 mm
side eccentricity:
1.0 mm
EN - 344
Thrust bearing
1. Check that the thrust bearing turns freely, with-
out jamming. Turn the thrust bearing while an axial
force is manually applied to the this bearing. Make
sure there are no abnormal signs of hardening or
obstacles.
2. Check the thrust bearing hub for signs of dam-
age or wear. Also check the contact surface of the
relevant stop and housing sliding section for signs
of damage or wear.
Thrust bearing hub stop
Pedale frizione
Removal
Remove the parts, following the numerical order shown in the figure.
Components:
EN - 345
1. Cover
2. Clutch cable adjusting nut
3. Clutch cable terminal
4. Clutch pedal shaft
5. Spring
6. Bushing
7. Clutch pedal
8. Clutch pedal protection
Inspection
Check the parts indicated below: replace those
defective parts.
Components:
A=Screw
B=Spacer
C=Spring
D=Pedal lever
Clutch cable
The clutch cable is the protection sheath type of
cable.
As a consequence, an increased liability level is
obtained, owing to an improved protection against
scoring due to possible foreign objects.
Installation
Fit the parts, following the numerical order shown in the figure.
EN - 346
Components:
1. Clutch pedal protection
2. Clutch pedal
3. Bushing
4. Spring
5. Clutch pedal shaft
6. Clutch cable
7. Clutch cable terminal
8. Clutch cable adjusting nut
9. Cover
Clutch pedal adjustment
Pedal fitting height
Set the distance between the floor and the centre
of the pedal upper surface to the specified value,
by means of the external adjusting nut A.
Characteristic
Pedal height:
137 - 147 mm
EN - 347
Free and residual travel of the pedal
1. Pull the sheath towards the bottom. Then, turn
the adjusting nut until reaching the position shown
in the figure.
Characteristic
Nut position:
20 mm
2. Position the adjusting nut, gear side, as follows:
Pull the cable with a force of 19.6 - 39.2 N in the
direction indicated by the arrow. At this stage, turn
the set nut until the interval between the adjusting
nut and the cable guide ring reaches the value 2.5
- 4 mm. Lock the adjusting nut, after aligning the
cable guide ring protrusion with the grooves of the
nut.
KEY:
1. Front
2. Sheath
3. Nut
4. Ring
3. Check the following adjustment values. Pedal
residual travel: 25 - 35 mm Pedal residual travel:
not less than 20 mm (Distance between the point
where the clutch is detached and the stop vertical
line).
Lubrication system
This section of the manual provides information to check the proper operation of the lubrication system.
The removal and fitting operations are described as well.
EN - 348
Oil pump
Oil pump
COMPONENTS
1. Oil pressure switch
2. Oil pump unit
3. Gasket
4. Oil filter
Oil pressure check
1. Remove the engine cover (only for van)
2. Disconnect the oil pressure switch connector.
3. Remove the oil pressure switch.
4. Fit a suitable oil pressure gauge.
5. Oil pressure measurement:
- start up the engine and let it warm up until reach-
ing the operation standard temperature.
- make sure that the oil pressure is within the pre-
scribed values.
- USE A LONG HEXAGONAL BOX-SPANNER FOR REMOV-
AL. - IF THE VALUE FOUND IS NOT WITHIN THE PRESCRI-
BED VALUES, CHECK AND REPAIR THE OIL PUMP.
Characteristic
Oil pressure values:
At idle speed: 20 kPa or more
At 3000 rpm: 245 - 490 kPa standard
6. Stop the engine.
7. Remove the oil pressure gauge.
8. Clean the threaded part of the oil pressure
switch.
9. Wrap the sealing tape around the threaded part
of the oil pressure switch.
EN - 349
10. Fit the oil pressure switch on the oil pump.
11. Connect the engine cable harness connector
to the oil pressure switch.
12. Start up the engine and check any oil leaks.
- USE A LONG HEXAGONAL BOX-SPANNER TO FIT THE
OIL PRESSURE SWITCH.
- THE NEW OIL PRESSURE SWITCH IS COATED WITH
SEALANT.
- NEVERTHELESS, WHEN REPLACING THE OIL PRES-
SURE SWITCH WITH A NEW ONE, REMOVE THE SEALANT
COMPLETELY BEFORE WRAPPING THE SEALING TAPE .
- MAKE SURE TO CLEAN THE OIL PUMP SIDE HOLE
THREADS BEFORE FITTING THE OIL PRESSURE
SWITCH.
Oil pressure switch - Cylinder block 1220
Removal
1. Place the engine unit on a suitable service
stand.
2. Remove the oil filtering element.
3. Remove bolts and nuts fixing the oil sump.
4. Separate the oil sump from the cylinder block.
5. Remove the oil filter undoing the fixing bolts.
6. Remove all the bolts fixing the oil pump unit.
7. Remove the oil pump from the cylinder block.
EN - 350
Removal
1. Remove the oil pump cover.
2. Remove the front oil seal.
3. Remove the oil pump rotor series.
4. Take out the cotter pin pushing the retaining
spring with the pliers.
5. Remove the spring retaining cap, the compres-
sion spring and oil pump valve.
- PLACE A SUITABLE CLOTH, ETC. ON THE SPRING RE-
TAINING CAP SO THAT IT CAN NOT JUMP OUT.
EN - 351
Checking each part
- Wash the parts to be removed using solvent for
cleaning.
- Check for possible damage to the pump body.
- Check for possible damage to the rotor
- Check for possible damage to the oil pump valve.
- Check for possible damage to the spring retaining
cap.
- Check for possible damage to the compression
spring and measure the relevant unloaded length.
Unloaded length prescribed value: 57 mm
- Apply engine oil onto the pump safety valve. In-
sert the valve in the pump and check for correct
operation.
- REPLACE EACH SINGLE DAMAGED PART. - REPLACE
THE COMPRESSION SPRING IF DAMAGED OR IN CASE
ITS UNLOADED LENGTH IS SHORTER THAN THE PRE-
SCRIBED VALUE. - REPLACE THE PUMP IF THE VALVE IS
NOT WORKING PROPERLY.
Measuring pump housing clearance, upper
part and side clearance.
1. Apply a thin layer of engine oil onto the surface
joining the oil pump assembly rotors and on the
rotor series. Fit the rotor series on the oil pump
assembly so that the drilled mark is visible from the
outside.
2. Rotor clearance - pump housing measurement
With a thickness gauge, measure clearance be-
tween the external rotor and the pump housing.
REPLACE THE OIL PUMP IF CLEARANCE EXCEEDS THE
PRESCRIBED VALUE.
Characteristic
Clearance:
0.20 - 0.28 mm
EN - 352
3. End clearance measurement
With thickness gauge, measure clearance be-
tween the end (tip) of the internal rotor and that one
of the external rotor.
REPLACE THE ROTOR SERIES IF CLEARANCE EXCEEDS
THE PRESCRIBED VALUE.
Characteristic
Clearance
0.16 - 0.24
4. Side clearance measurement
With a rectified bar section and a thickness gauge,
measure side clearance between rotors and the oil
pump housing.
PRESCRIBED VALUE.
Characteristic
Maximum clearance allowed:
0.04 - 0.08 mm
WEAR CHECK
Check if the pump cover rotor series connection
surface is worn.
- REPLACE THE OIL PUMP COVER IF WORN.
Fitting
1. Apply engine oil onto the valve and insert, af-
terwards, the valve inside the oil pump body.
2. Insert the compression spring and or the spring
retaining cap inside the oil pump body.
N.B.
- WASH THOSE PARTS TO BE FITTED USING SOLVENT
FOR CLEANING. DRY THEM BLOWING COMPRESSED
AIR. - WHEN COMPRESSED AIR IS USED, PROTECT EYES
BY WEARING PROTECTIVE GOGGLES. - FIT THE SPRING
RETAINING CAP SO THAT THE PROTRUDING PART IS
PLACED ON THE COMPRESSION SPRING SIDE.
EN - 353
3. Insert a new split pin in the lock while it is
stretched with pliers, etc. Separate the end of the
split pin until reaching an anchor shape.
4. Insert a new oil seal if the one being used is
damaged, with a hydraulic press.
THE OIL SEAL REMOVAL AND FITTING.
- MAKE SURE THAT THE OIL SEAL IS NOT FITTED IN AN
INCLINED POSITION .
5. Apply engine oil onto the rotor series. Fit the ro-
tor series on the pump body so that the two refer-
ence marks are facing outwards.
6. Fit the oil pump cover and tighten it to the pre-
scribed torque.
EN - 354
7. Turn the rotor by hand. Make sure that the rotor
turns slowly. Otherwise, service the oil pump.
Installation
1. Remove the gasket from the oil pump and from
the cylinder block.
2. Apply sealant onto the fitting surface of the cyl-
inder block oil pump, as indicated in the figure.
-
3. Apply engine oil onto the oil seal internal sur-
face.
4. Replace the O-ring A of the oil pump with a new
one.
5. Fit the oil pump on the cylinder block with fixing
bolts
CAUTION
- BE CAREFUL NOT TO DAMAGE THE CRANKSHAFT OIL
SEAL DURING THE OIL PUMP FITTING.
- BE CAREFUL NOT TO LET THE O-RING FALL DURING
THE OIL PUMP FITTING.
Oil pump - Cylinder block 69
EN - 355
6. Fit the oil filter on the cylinder block interposing
a new gasket.
Oil filter - Cylinder block 1522
7. Fix the gaskets of the oil sump to the cylinder
block.
N.B.
- THE OIL SUMP GASKETS ARE LOCATED IN TWO
POINTS: ONE ON THE OIL PUMP SIDE AND THE OTHER
ON THE FLYWHEEL SIDE. FIT THE GASKET PROTRUDING
PART IN THE SPECIFIC SECTION OF THE CYLINDER
BLOCK.
8. Apply the sealant onto the fixing section of the
oil sump cylinder block as shown in the figure on
the right.
N.B.
- MAKE SURE THAT THE SEALANT IS APPLIED TO BOTH
OIL SUMP GASKET ENDS, SO THAT THE PARTS ON
WHICH IT IS APPLIED CAN OVERLAP.
9. Fit the oil sump on the cylinder block with bolts
and fixing nuts.
10. Tighten in the same way, the bolts and nuts
fixing the oil sump to the prescribed torque in two
or three stages.
EN - 356
Checks
Checking each part
- Wash the parts to be removed using solvent for
cleaning.
- Check for possible damage to the pump body.
- Check for possible damage to the rotor
- Check for possible damage to the oil pump valve.
- Check for possible damage to the spring retaining
cap.
- Check for possible damage to the compression
spring and measure the relevant unloaded length.
Unloaded length prescribed value: 57 mm
- Apply engine oil onto the pump safety valve. In-
sert the valve in the pump and check for correct
operation.
- REPLACE EACH SINGLE DAMAGED PART. - REPLACE
THE COMPRESSION SPRING IF DAMAGED OR IN CASE
ITS UNLOADED LENGTH IS SHORTER THAN THE PRE-
SCRIBED VALUE. - REPLACE THE PUMP IF THE VALVE IS
NOT WORKING PROPERLY.
Measuring pump housing clearance, upper
part and side clearance.
1. Apply a thin layer of engine oil onto the surface
joining the oil pump assembly rotors and on the
rotor series. Fit the rotor series on the oil pump
assembly so that the drilled mark is visible from the
outside.
2. Rotor clearance - pump housing measurement
With a thickness gauge, measure clearance be-
tween the external rotor and the pump housing.
PRESCRIBED VALUE.
Characteristic
Clearance:
0.20 - 0.28 mm
EN - 357
3. End clearance measurement
With thickness gauge, measure clearance be-
tween the end (tip) of the internal rotor and that one
of the external rotor.
REPLACE THE ROTOR SERIES IF CLEARANCE EXCEEDS
Characteristic
Clearance
0.16 - 0.24
4. Side clearance measurement
With a rectified bar section and a thickness gauge,
measure side clearance between rotors and the oil
pump housing.
PRESCRIBED VALUE.
Characteristic
Maximum clearance allowed:
0.04 - 0.08 mm
WEAR CHECK
Check if the pump cover rotor series connection
surface is worn.
- REPLACE THE OIL PUMP COVER IF WORN.
Oil cartridge
Oil filter fitting
1. Apply a reduced quantity of engine oil onto the
oil filter gasket.
EN - 358
2. Screw the oil filter until the gasket makes con-
tact with the oil pump.
3. Then, turn once more the oil filter completely
(360).
Sensore pressione olio
Oil pressure warning light
Check if the oil pressure warning light turns on by
turning the ignition switch to ON.
- IF THE WARNING LIGHT DOES NOT TURN ON, CHECK
THAT THE BULB IN THE PANEL IS NOT BURNED. (REFER
TO THE SECTION " ELECTRICAL SYSTEM COMPONENTS"
- IF THE WARNING LIGHT TURNS ON WHEN THE ENGINE
IS RUNNING, CARRY OUT THE FOLLOWING CHECKS:
(FIRST OF ALL, MAKE SURE THAT THE ENGINE OIL IS AT
AN ADEQUATE LEVEL).
pressure switch fitting
1. Clean the threaded part of the pressure switch.
Wrap a sealing tape around the threaded part.
N.B.
- THE NEW PRESSURE SWITCHES ARE COATED WITH
SEALANT. THEREFORE, WHEN THE PRESSURE SWITCH
IS REPLACED WITH A NEW ONE, FIRST, REMOVE THE
COATING COMPLETELY SINCE THE PRODUCT LOOSES
ITS CHARACTERISTICS WITH TIME. ALSO CLEAN THE
THREADED HOLES WHERE THE SWITCH IS FITTED.
EN - 359
2. Tighten the oil pressure switch to the specified
torque value, using a box-spanner.
Cooling system
Coolant pump
Water pump fitting
1. Fit a new water pump gasket on the cylinder
block.
2. Fit and tighten the water pump to the specified
torque value.
N.B.
- WHEN STUD BOLTS ARE LOOSENED OR REPLACED,
APPLY THE RECOMMENDED PRODUCT ONTO THE
THREADED SECTION FROM THE CYLINDER BLOCK
SIDE.
pound
-
EN - 360
Water pump pulley test
1. Visually check the water pump pulley.
Check the water pump pulley attach-
ment seat for deformations or worn
areas.
Check the belt groove for deformations
or worn areas. Replace the water
pump pulley, if necessary.
Injection fuel system
Fuel filter
Fuel filter
Fuel filter replacement
- DO NOT OPERATE NEAR NAKED FLAMES. DO NOT WORK NEAR THE OPEN TANK. FAILURE
TO OBSERVE THIS INDICATIONS CAN CAUSE FIRE.
1. Check the ignition switch is placed on OFF.
2. Open the fuel tank cap.
3. Place a collecting container or a cloth under the
fuel filter.
4. Loosen the fuel filter nut slowly, avoiding fuel
splashes.
- HOLD THE FUEL FILTER WITH A WRENCH OR SIMILAR
OBJECT TO PREVENT ITS ROTATION.
- CAREFULLY AVOID FUEL SPLASHES ON THE BODY-
WORK OR RUBBER PARTS, ETC., SINCE FUEL LEAKAGE
WILL BE PROFUSE.
KEY:
A= Fuel
B= Filter
5. Disconnect the pipe clamp from the fuel filter.
6. Disconnect the fuel pipe from the filter.
7. Remove the pipe clamp and fit a new one.
8. Remove the fuel filter unscrewing both fastening
bolts.
9. Install the new fuel filter screwing both fastening
bolts.
Cylinders lock for water inlet 5.9 8.8 Nm
10. Connect the pipe to the fuel filter, fasten the new clamp in the correct position.
EN - 361
11. Manually tighten the nut on the fuel filter.
12. Tighten the nut to the prescribed torque.
- PREVENT FILTER ROTATION BY HOLDING IT WITH A WRENCH OR SIMILAR TOOL. - NEVER
REUSE AN OLD GASKET. FAILURE TO OBSERVE THIS SAFETY MEASURE CAN CAUSE FIRE
AFTER FUEL LEAKAGE.
Fuel filter fixing nut 34 43
13. Close the fuel tank cap.
14. Remove the collecting container or cloth.
15. Place the ignition switch on ON/OFF for four or five times, every three seconds.
16. After replacement, check that there is no fuel leaks from the fuel filter.
Visually inspect the fuel supply system and the fuel filter checking there are no cracks, leaks, loosen
connections or distortions.
Cooling Circuit
This section of the manual provides information to check the proper operation of the cooling system.
The removal and fitting operations are described as well.
Conceptual diagram
Cooling system diagram
The cooling system is a water and forced circulation type of system. In addition, it uses a cooling electric
fan and by-pass cooling system, where there is thermostat equipped by an inlet by-pass valve. The
cooling system comprises the radiator, water pump, thermostat, cylinder head, cylinder block, water
pipe and the relevant fittings.
- FOR COOLING, USE SWEET WATER (DE-IONISED) WHICH DOES NOT CONTAIN MINERAL
SALTS, CALCIUM, MAGNESIUM ETC. .
- IF THE COOLANT SLIGHTLY TOUCHES PARTS OF THE BODYWORK, WASH THOROUGHLY.
- NEVER OPEN THE RADIATOR CAP WHEN THE COOLING WATER IS HOT.
- THE RADIATOR INSIDE IS UNDER PRESSURE WHEN THE COOLING WATER IS HOT. IF THE
RADIATOR CAP IS REMOVED, THE COOLING WATER MAY SPLASH OUT, PROBABLY CAUS-
ING INJURIES AND BURNS
EN - 362
Radiator cleaning
Using water or vapour jets, remove the residues and the dust from the external radiator.
- WHEN A VAPOUR JET IS USED AT HIGH PRESSURE, BE CAREFUL NOT TO DEFORM THE
RADIATOR FINS.
- IF THE JET PRESSURE IS 2.9 - 4.9 MPA (3-5 BAR), KEEP A DISTANCE EXCEEDING 40 - 50 CM
BETWEEN THE RADIATOR AND THE NOZZLE.
- WARNING, DIRECT THE JET TO A RIGHT ANGLE WITH RESPECT TO THE RADIATOR.
- FAILURE TO OBSERVE THESE RULES CAN CAUSE DEFORMATION OF THE RADIATOR FINS.
Radiator cap check
1. With a suitable device, (tester for radiator cap
testing) check the sealing valve opening pressure:
59 -103 kpa (0.6-1.0 bar). If this is not so, replace
the radiator cap.
N.B.
- NEVER OPEN THE RADIATOR CAP WHEN THE ENGINE
IS STILL HOT. FAILURE TO OBSERVE THIS PRECAUTION
MAY CAUSE BURNS.
EN - 363
2. Check the radiator cap gasket for possible dam-
age. If this is so, replace the radiator cap.
3. With your fingers lift the cap valve. Check that
the valve operates properly. In case the valve does
not operate properly, replace the radiator cap.
Cooling circuit check for possible water leaks
1. Fill the radiator with coolant and apply the radi-
ator testing device.
2. Warm up the engine.
3. Apply a pressure of 88 kPa (0.9 bar) to the cool-
ing system with radiator testing device.
4. In case the pressure lowered, check pipes, the
radiator, water pump, heating, for possible leaks.
If no leaks are detected, check: heating radiator,
block, head and heat exchanger for possible leaks.
Check the pipes for possible deterioration, break-
ing or damage. Replace the defective parts.
5. Remove the radiator testing device from the ra-
diator.
6. Refit the radiator cap
- NEVER REMOVE THE RADIATOR CAP OR BLEEDING
CAP WITH THE COOLANT STILL HOT. FAILURE TO OB-
SERVE THIS PRECAUTION CAN CAUSE BURNS.
EN - 364
Thermostatic valve
Thermostat removal
2. Drain the coolant.
3. Remove the two sleeves from the thermostat
cover.
- NEVER OPEN THE RADIATOR CAP AND/OR THE DRAIN-
AGE PLUG WHEN THE FLUID IS HOT. - COVER THE AL-
TERNATOR TO AVOID THAT THE COOLANT GETS INTO
THE ALTERNATOR.
4. Remove the 3 thermostat cover screws.
Thermostat inspection
1. Make sure that the thermostat valve is com-
pletely closed at an ambient temperature of 20C
and that the spring has no clearance. Replace the
thermostat, if the valve is open or if the spring has
clearance.
EN - 365
2. Check the thermostat sealing ring for possible
damage or breaking. Replace the thermostat if the
sealing ring shows signs of damage or breaking.
3. Immerse the thermostat in the water. Warming
up very slowly, check the opening start tempera-
ture.
Replace the thermostat if characteristics do not
comply
Characteristic
Valve opening temperature in C
82 - 86C
Valve lifting
8.5 mm or more at 97C
Thermostat fitting
1. Fit the thermostat with the bleeding pin placed
towards the upper part of the engine.
- THE THERMOSTAT MUST BE FITTED WITH THE BLEED-
ING PIN UPWARDS. FAILURE TO OBSERVE THIS PRE-
CAUTION COULD CAUSE A MALFUNCTION IN THE
ENGINE OPERATION.
2. Fit the thermostat cover.
Cover - Thermostat 5.9 8.8
EN - 366
3. Filling with coolant.
4. Connect the battery negative (-) terminal.
5. Start the engine and check for possible leaks. If
there are leaks, repair the point at which the leak
is detected.
Radiatore
Radiator removal
2. Drain the coolant as follows:
Set the heating control lever to "hot".
Remove the front panel gasket.
Remove the radiator cap.
- NEVER OPEN THE RADIATOR CAP AND/OR THE DRAINAGE PLUG WHEN THE COOLANT IS
HOT.
KEY:
1. Cap for heating air breather pipe.
2. Engine side cap
3. Radiator cap
4. Heating
5. Radiator
6. Engine
EN - 367
Remove the drainage plug placed near
the radiator inlet sleeve (right housing)
and on the outlet pipe fitting from the
radiator.
Remove cap 2 on the engine side and
cap 1 for the heating air breather pipe
at the upper part of the engine.
3. Remove the front bumpers.
4. Remove the reinforcement.
5. Disconnect the inlet pipe, outlet pipe and the
water pipe for heating from the radiator.
6. Disconnect the radiator fan connector.
7. Remove the right and left supports of the radi-
ator taking out the 4 fixing screws.
8. Remove the radiator, the relevant fan and the
fan protection.
9. Remove the radiator fan and the relevant radi-
ator protection.
- BE CAREFUL NOT TO LET THE RADIATOR FALL WHEN
THE RADIATOR SUPPORT IS REMOVED.
EN - 368
Radiator fitting
1. Fit the radiator fan and the relevant protection
on the radiator and tighten the fixing nuts.
2. Insert the right and left supports of the radiator
on the radiator.
3. Fit the radiator with the relevant supports on the
vehicle and tighten the 4 screws fixing the radiator
supports.
4. Connect the radiator fan connector.
5. Connect the radiator inlet, outlet pipe and the
water pipe for the heater.
6. Fit the reinforcement on the vehicle.
7. Fit the front bumpers on the vehicle.
9. Refill with coolant.
10. Fit the front panel gasket on the vehicle.
EN - 369
Coolant temperature sensor
Radiator thermoswitch removal
2. Drain the coolant.
3. Disconnect the radiator thermoswitch connec-
tor.
4. Remove the radiator thermoswitch from the ra-
diator pipe.
Radiator thermoswitch inspection
Radiator thermoswitch specifications:
The figure shows the hysteresis cycle of the ther-
moswitch.
1. Connect an ohmmeter between terminals A and
B of the radiator thermoswitch.
2. Immerse the switch heat measuring section in a
water bath.
EN - 370
3. Heat the water until reaching a temperature of
93C. Check continuity between terminals A - B of
the radiator thermoswitch. If there is no continuity,
carry out the following checks.
4. Take the water temperature to 97C. Check
continuity between terminals A and B of the
switch. If there is continuity, replace the switch.
there is no continuity between terminals A - B of
the switch. If there is continuity, carry out the fol-
lowing checks.
there is no continuity between terminals A - B of
the switch. If there is continuity, replace the switch.
Radiator thermoswitch fitting
1. Clean the threaded part of the switch and after-
wards wrap the thread with the adhesive tape.
2. Fit the radiator thermoswitch on the radiator.
Radiator - Water thermal switch 24.5 5
3. Fill with coolant.
EN - 371
5. Start up the engine and check any water leaks.
Water pump
Water pump removal
2. Remove the lower crankcase.
3. Drain the coolant. Open the radiator cap and the
drainage plug and let the coolant off in a container.
- NEVER OPEN THE RADIATOR CAP AND/OR THE DRAIN-
AGE PLUG WHEN THE ENGINE IS HOT.
4. Remove the timing belt
5. Remove the water pump removing the relevant
fixing screws and nuts.
EN - 372
Inspecting parts relating to the water pump
1. Check if the water pump pulley is damaged or
deformed. Replace the water pump if it damaged
or deformed.
2. Check if the pump rotor is damaged or de-
formed.
3. Make sure that water pump rotates properly by
hand. If it does not rotate properly, replace it.
4. Check for signs of damage and wear on the cyl-
inder block surface which is coupled with the pump
rotor. If damage is detected, replace the cylinder
block.
COMPONENTS:
1. Sealing ring
3. Water pump
4. Gasket
EN - 373
5. Cylinder block
Water pump sealing test
1. Visually check the water pump.
The mechanical sealing section for wa-
ter leaks.
The water pump rotating pallet for pos-
sible corrosion, deformations or
cracks.
The water pump attachment surface
for scores.
The attachment seat of the pump pul-
ley for possible wear.
Replace the water pump, if necessary.
2. Check if there is excessive clearance or noise
of the water pump bearing and the pulley attach-
ment section.
Replace the water pump, if necessary.
EN - 374
Water pump fitting
1. With a scraper, remove the gasket residues
from the cylinder block
2. Remove the gasket from the water pump, using
a scraper for gaskets.
3. Fit a new gasket on the cylinder block.
4. Fit the water pump on the cylinder block. Tight-
en, in two or three stages, the fixing screws and
nuts, to the prescribed torque.
N.B.
- AFTER TIGHTENING THE BOLTS, MAKE SURE THAT
THE PUMP ROTATES PROPERLY.
5. Fit the timing belt
EN - 375
6. Fill with coolant.
7. Fit the lower crankcase.
EN - 376
INDEX OF TOPICS
INIECTION SYSTEM IS
This section of the manual comprises information regarding to safety measures and the Injection system
diagnosis.
Precauzioni
GENERAL SAFETY MEASURES
INSTRUCTION FOR MANUAL USE: The manual is drawn up for the areas where a type-approval
certificate is issued according to the approval of EC exhaust emissions. Therefore, the assignment,
reading, clearing of failure codes and checking, repair and confirmation procedures, are different from
the procedures carried out up to now.
And therefore, follow the instructions described below: 1. Using the diagnostic tester or OBD II general
scanning device.
2. Note regarding failure codes: to read or clear the 4 digit failure codes (e.g. P0105) assigned according
to the ISO standards, always use a tester or the device described in point 1. Also use the tester or the
device to turn the warning light off.
- AN OBD II GENERAL SCANNING DEVICE IS A SCANNING DEVICE COMPLYING WITH THE
FORMAT ISO14230 (KWP2000).
- WHEN USING AN OBD II GENERAL SCANNING DEVICE, NOT ALL THE FAILURE CODES (4
DIGIT CODES) CAN BE READ. TAKE INTO ACCOUNT THAT ONLY THE FAILURE CODES IN
WHICH " ZERO" FOLLOWS LETTER " P" CAN BE READ, FOR EXAMPLE POXXX.
- IN THIS MANUAL, THE AREAS WHERE THE TYPE-APPROVAL CERTIFICATION IS ISSUED
ACCORDING TO THE APPROVAL OF EC EXHAUST EMISSIONS ARE INDICATED WITH " EU
SPECIFICATIONS" .
Specific tooling
020461Y Diagnostic tester kit DS-21 (ex 09991-87301-000)
INSTRUCTIONS TO USE THE VEHICLE EQUIPPED WITH CATALYTIC CONVERTER
RECOMMENDATIONS: 1. If there is a great quantity of unburned gases in the catalytic converter,
an overheating can be detected with the consequent fire hazard. To prevent this type of incon-
venient strictly follow the instructions and inform the customer properly.
2. With vehicles equipped with catalytic converter use only unleaded petrol.
3. Avoid running the engine at idle speed for a long time. Do not run the engine at idle speed for
a more than 20 minutes.
4. Check and repair the vehicle immediately if the idle speed or idle is unstable or if failures are
detected in the system, failure to observe this safety measure can cause fire hazard.
5. Procedure to test the electric discharge.
The electric discharge must be carried out only when it is strictly necessary; complete the
test as soon as possible.
Do not run the engine with no gear engaged during the test.
Be careful to lock the fuel supply during the test.
Iniection System PORTER 1.3 16V
IS - 378
6. Do not run the engine with the fuel tank almost empty. Failure to observe this safety measure
causes an irregular ignition. Besides, an excessive charge to the catalytic converter could dam-
age it .
7. Avoid riding downhill in neutral with the ignition switch set to OFF. Besides, avoid braking
for a long time.
8. Avoid disposing of the catalytic converter with other parts contaminated with petrol or diesel.
WARNING
- CHECK AND REPAIR THE VEHICLE IMMEDIATELY IF THE IDLE IS TOO HIGH OR UNSTABLE
OR IF MALFUNCTIONS ARE DETECTED IN THE SYSTEM. FAILURE TO OBSERVE THIS SAFETY
MEASURE CAN CAUSE FIRE HAZARD. - IF THERE IS A GREAT QUANTITY OF UNBURNED
GASES IN THE CATALYTIC CONVERTER, AN OVERHEATING CAN BE DETECTED WITH THE
CONSEQUENT FIRE HAZARD. TO PREVENT THIS TYPE OF PROBLEM, STRICTLY FOLLOW THE
INSTRUCTIONS ON THE SUBJECT. IN ADDITION, ALSO EXPLAIN TO THE CUSTOMERS WHICH
SAFETY MEASURES MUST BE ADOPTED.
INSTRUCTIONS FOR THE MOBILE COMMUNICATION SYSTEM
In case of vehicles with an engine equipped with a mobile communication system, as two-way wireless
telephones or mobile phones, be careful to follow the safety measures indicated below.
1. Fit the aerial as far as possible from the electronic control unit and from the vehicle electronic control
system sensors.
2. The aerial wire must be at least at 30 cm from the electronic control unit and from the vehicle electronic
control system sensors. For further information regarding the electronic control unit and the sensors,
refer to the diagram about the component layout in the relevant paragraph.
3. Do not wrap the aerial power supply wires with other wires. Avoid placing the aerial feeder in direction
to other wires, when this is possible.
4. Be careful to adjust the aerial and the power supply wires properly.
5. Never fit a mobile communication system too hard.
INJECTION SYSTEM CIRCUIT CHECK
1. Before connecting or disconnecting the connec-
tors and terminals, place the ignition switch to OFF
or disconnect the battery negative (-) terminal.
Otherwise, there will be an interrupted wire in the
cable harness and the failure-free function will be
activated.
On the other hand, when the battery negative (-)
terminal is disconnected, the diagnosis code is
cleared. Therefore, confirm the diagnosis code be-
forehand, if necessary.
PORTER 1.3 16V Iniection System
IS - 379
2. Avoid pulling the wires to disconnect the con-
nector. Hold the connector properly after releasing
it and pull slightly. To connect the connector, insert
it until the insertion click is not felt.
3. Do not touch the terminal contacts with the
hands.
4. Prevent contact between the two testing probes
applied to the terminal supplied electrically, to
avoid short circuits.
5. When the connector is connected to the elec-
tronic control unit, never place an ohmmeter be-
tween the control unit connector and the sensor or
the actuator. Failure to observe this safety meas-
ure can damage the electronic control unit, the
sensor or the actuator.
6. If a testing probe is applied to the connector, be
careful to place on its rear part (cable harness
side). In case of connectors to which a testing
probe can not be connected on the rear part, such
as waterproof connectors, apply the testing probe
on the connector side, being careful not to bend
the male terminal or to open the female terminal.
7. Use a voltmeter/ohmmeter with internal impe-
dance equal to at least 10 k Ohm/V. If a voltmeter/
ohmmeter with internal impedance below 10 k
Ohm/V is used, failures can be detected or there
can be incorrect measurements.
IS - 380
8. While checking the condition of terminals, verify
that the male terminal is not bent and that the fe-
male terminal is not excessively open. Besides,
check the locking of both terminals, and that there
is no rust, dust, etc.
9. Before measuring voltage on each terminal,
check the battery voltage is at least 11 V. If the
check is performed with a low battery voltage, the
diagnosis could be incorrect.
Connessione Attrezzo Specifico (SST)
USING THE DIAGNOSTIC TESTER or OBD II GENERAL SCANNING DEVICE
- OBSERVE THE FOLLOWING INSTRUCTIONS TO OPERATE IN GREATER SAFETY CONDI-
TIONS:
- BEFORE USING THE DIAGNOSTIC TESTER or OBD II GENERAL SCANNING DEVICE, READ
THE USER MANUAL CAREFULLY.
- DURING THE VEHICLE RIDING WITH THE OBD II GENERAL SCANNING DEVICE OR DIAG-
NOSTIC TESTER CONNECTED TO THE VEHICLE, PLACE THE CABLES SO THAT THEY DO NOT
INTERFERE WITH DRIVING MANOEUVRES (IT MEANS, THE CABLES MUST NOT BE NEAR
FEET, PEDALS, STEERING AND GEARSHIFT LEVER).
- DURING THE TEST RIDING WITH THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC
TESTER, TWO PERSONS ARE NECESSARY. ONE PERSON DRIVES THE VEHICLE, WHILE THE
OTHER ACTIVATES THE ONE OF THE DIAGNOSIS INSTRUMENTS.
USING THE ENGINE CHECKING SYSTEM
1. The electronic control unit, sensors, etc. are
precision components. Be careful not to hit these
parts during fitting and removal operations. Do not
use the parts have been suddenly hit (for example,
if they fell down the floor).
2. If the test is performed on a rainy day or after
the vehicle has been washed, be careful to avoid
water infiltration and not to wet the electronic con-
trol unit, sensors, actuators, etc.
3. Never disconnect the connector from the battery
terminal during the engine operation. When the
connector is disconnected from the battery termi-
nal, an electric discharge could be generated (ap-
prox. 100V), which could damage the electronic
control unit.
IS - 381
4. Do not reverse the battery polarity, when the
connectors are connected. Failure to observe this
safety measure could cause the immediate break-
ing of the battery.
5. Never remove the electronic control unit cover
or the bracket on the electronic control unit side.
Also avoid touching the fixing screws.
6. If an electronic control unit malfunction is detected and the vehicle is repaired with its replacement,
refit the control unit previously removed (that defective) to confirm the original malfunction. At this stage,
it is possible to establish once and for all that the electronic control unit is not working properly.
7. Rpm indicator sensor connection. Connect the rpm indicator sensor to the measurement terminal of
the special tool. WARNING: THIS IS INVALID IF THE RPM INDICATOR SENSOR IS OF THE PICK-
UP TYPE. PREVENT THE CONTACT OF THE SPEED SENSOR WITH THE GROUND, SINCE THE
IGNITION SPARK PLUG AND/OR IGNITION COIL COULD BE DAMAGED. SOME TYPES OF RPM
INDICATORS ARE NOT FIT FOR THE VEHICLE IGNITION SYSTEM. THEREFORE, CHECK IF THE
RPM INDICATOR IS COMPATIBLE WITH THE VEHICLE IGNITION SYSTEM.
Specific tooling
KEY:
1. Special tool connector
A. Rpm indicator terminal
GND. Chassis ground
SST. Special tool
DLC. Data link connector on the vehicle 2. SST
SPECIAL TOOL CONNECTION
INTERFACE CABLE HARNESS TO CHECK
THE ELECTRONIC INJECTION SYSTEM
To measure the voltage of the electronic control
unit terminal with its connector connected to the
engine control unit, connect the special tool fol-
lowing the procedure described below:
1. Set the ignition switch to OFF. Or disconnect the
battery from the negative (-) terminal, with the ig-
nition switch set to OFF. Disconnect the battery
ground lead from the negative (-) terminal.
IS - 382
- THE NUMBER OF THE SPECIAL TOOL CONNECTOR
TERMINAL IS THE SAME THAT THE ELECTRONIC CON-
TROL UNIT CONNECTOR NUMBER (SEE TERMINAL LAY-
OUT OF THE INJECTION SYSTEM ELECTRONIC CON-
TROL UNIT) - STORE THE ERROR CODE BEFORE
DISCONNECTING THE BATTERY CABLE TO AVOID THAT
IT IS CLEARED WHEN THE CABLE IS DISCONNECTED.
2. Disconnect connectors, B, C, D, from the ECU
electronic control unit, placed under the glove-box
on the passenger side.
3. Connect the special tool indicated below be-
tween the cable harness connectors B and con-
nectors of ECU A.
Specific tooling
020463Y ECU-EFI interface cable harness to
check the injection system electrical values.
4. Reconnect the battery ground lead to the negative terminal (-).
N.B.
- WHEN THE INJECTION SYSTEM ELECTRONIC CONTROL UNIT CONNECTORS ARE DISCON-
NECTED OR CONNECTED, BE CAREFUL THAT THE BATTERY IS DISCONNECTED, WITH THE
IGNITION SWITCH AND ALL THE ACCESSORY SWITCHES SET TO OFF.
- WHEN FITTING THE NEW BATTERY, BE CAREFUL NOT TO REVERSE POLARITY. FAILURE
TO OBSERVE THIS SAFETY MEASURE COULD CAUSE A MALFUNCTION OF THE ELECTRONIC
CONTROL UNIT.
- BEFORE USING THE SPECIAL TOOL, CHECK THERE ARE NO SHORT CIRCUITS OR INTER-
RUPTED WIRES BETWEEN TERMINALS<.
Data link connector (common destinations)
The vehicle engine electronic control unit adopts the ISO 14230 protocol (Euro-OBD). As regards the
position, shape of the connector and pin layout, the data link connector complies with the standards
ISO 15031-3 (SAEJ 1962) and the format ISO 14230. The OBD II serial data line (ISO 14230 K line) is
used for the OBD II general scanning device or for the diagnostic tester DS-21, to allow communication
with the electronic control unit.
IS - 383
DLC CONNECTOR KEY
16 Battery powered
13 ECU - T
12 EFI - T
9 REV - Engine revs signal
7 OBD II serial data line (ISO 14230 K line)
Present during transmission
5 ECU ground
4 Chassis ground
N.B.
WITH THE CABLE OF THE DIAGNOSTIC TESTER DS-21 CONNECTED TO THE DATA LINK CON-
NECTOR BY MEANS OF THE CONTROL UNIT SELF-DIAGNOSIS CONTROL CABLE HARNESS,
SET THE IGNITION SWITCH TO ON. IF THE TESTER VOLTAGE INDICATOR DOES NOT TURN
ON, PERFORM THE FOLLOWING CHECKS AND REPAIR THE PARTS NOT WORKING PROPER-
LY.
Specific tooling
CONNECT THE TESTER DS-21 TO ANOTHER VEHICLE, SET THE IGNITION SWITCH TO ON:
1. When the voltage indicator of the diagnostic tester DS-21 turns on: Vehicle side operation failure.
Check the data link connector, +B and Ground. - BAT terminal voltage check - Continuity check
between terminals E and Ground.
2. When the voltage indicator of the diagnostic tester DS-21 does not turn on: Operation failure of the
diagnostic tester DS-21
A =voltage indicator (switch section)
IS - 384
Descrizione del sistema
COMPONENT LOCATION (EU SPECIFICATIONS)
1. Data link connector between the ECU and the Diagnostic tester (DLC ). 2. Remote control unit (fuel
pump, main ECU, etc...) 3. Intake air temperature sensor(IAT) 4. Throttle valve position sensor (TPS)
5. Manifold absolute pressure sensor (MAP) 6. EGR valve 7. Fuel pump 8. EGR vacuum modulator
9. Vacuum switching valve for EGR valve(VSV 1) 10. Engine coolant temperature sensor (ECT) 11.
Engine revolution sensor (RPM) 12. Rear oxygen sensor (OX2 lambda probe) 13. Ignition unit 14.
Ignition coil 15. Front oxygen sensor (OX1 lambda probe) 16. Fuel pressure regulator 17. Injector
18. Electronic injection control unit (ECU EFI - DENSO) 18 D. Emission control unit (ECU - DRACO)
19. Vacuum switching valve to increase idle speed(VSV 2) 20. vehicle speed sensor in the instrument
panel 21. Vacuum switching valve for recovery of fuel vapours (VSV )
IS - 385
INJECTION SYSTEM BASIC DIAGRAM (FOR EU SPECIFICATIONS) 1. Data link connector between
the ECU and the Diagnostic tester(EOBD socket) 2. Vehicle speed sensor, integrated in the Instrument
panel. 3. Injection system electronic control unit; with a built-in atmospheric pressure sensor (ECU -
EFI) 3D. Electronic control unit of the emission system. (ECU - DRACO) 4. Front oxygen sensor heater/
front oxygen sensor (OXH1/OX1) 5. Malfunction indicator light (MIL) 6. Ignition coil 7. Fuel pressure
regulator 8. Ignition unit; with ionic current measurement. 9. Cam angle position sensor (RPM) 10. EGR
valve 11. Surge tank 12. Injector (1# ,2#, 3#, 4#) 13. Engine coolant temperature sensor (ECT) 14. Rear
oxygen sensor heater/Rear oxygen sensor (OXH2/OX2) 15. Auxiliary air valve, controlled by the ther-
mostat. 16. Throttle body 17. Activated carbon filter (CANISTER) 18. Fuel tank 19. Vacuum switching
valve of fuel vapours (VSV) 20. Air filter 21. Intake air temperature sensor (IAT) 22. Throttle valve
position sensor (TPS) 23. Manifold absolute pressure sensor (MAP) 24. Vacuum modulator for EGR
25. Vacuum switching valve to increase idle speed (VSV2) 26. Vacuum switching valve for EGR valve
(VSV1)
IS - 386
ECU-DRACO CONNECTOR LAYOUT
IS - 387
DRACO-DENSO ECU interface diagram
EFI - DRACO ECU INTERFACE DIAGRAM
1. Emission control unit (DRACO). 2. EFI-ECU control unit (DENSO). 3. connector to program the
DRACO control unit 4. EFI-DRACO connection cable harness 5. To the engine cable harness 6. To the
vehicle cable harness
IS - 388
* Connector from front view, opposed side to cable output
** COLOUR TABLE
B = BLACK = NERO G = GREEN= VERDE R = RED = ROSSO L = LIGHT BLUE = AZZURRO O =
ORANGE = ARANCIO P = PINK = ROSA Y = YELLOW = GIALLO W = WHITE = BIANCO V =
VIOLET= VIOLA Br = BROWN = MARRONE Gr = GREY = GRIGIO
Disposizione terminali
Disposizione del morsetto dell'unit di controllo elettronica del sistema di iniezione
IS - 389
CONNECTOR A (CONNECTED TO THE ENGINE ELECTRICAL SYSTEM )
1 21 (N1+) -
2 22 (N2+) Cam angle sensor (+)
3 23 (E1) Sensor unit ground
4 24 (#40) Injector (cylinder No.4)
8 28 (OCV+) -
9 51 (N1-) -
10 52 (N2-) Cam angle sensor (-)
11 53 (KNK) -
12 54 (ISC) -
13 55 (ALTC) -
14 56 (VSV2) Vacuum switching valve to increase idle speed
15 57 (IG4) Ignition signal (cylinder No.4)
19 61 (OCV) -
20 79 (PRG) Vacuum switching valve to control bleeding
21 80 (V8V1) Vacuum switching valve for EGR
22 81 (ALT) -
23 82 (E01) Power supply system ground
IS - 390
CONNECTOR B (CONNECTED TO THE ENGINE ELECTRICAL SYSTEM )
1 14 (ICMB) Ignition unit (with ionic current measurement)
2 15 (PIM) Pressure sensor signal
3 16 (VC) Throttle valve sensor power supply
4 17 (E2) Sensor ground
5 18 (FCCP) -
6 19 (VFP) -
7 20 (OXH1) Front oxygen sensor heater
8 43 (IE) Ionic current sensor ground
9 44 (VTH) Throttle valve sensor
10 45 (THW) Engine coolant temperature sensor
11 46 (VCPM) Pressure sensor power supply
12 47 (E2PM) Pressure sensor ground
13 48 (ACLK) -
14 49 (ACEN) -
15 50 (OXH2) Rear oxygen sensor heater
16 74 (0X2) -
17 75 (0X1) Front oxygen sensor
18 76 (THA) Intake air temperature sensor
19 77 (ACVR) -
20 78 (PST) -
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CONNECTOR C (CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM )
1 8 (SI01) Diagnostic tester
2 9 (T) Test terminal
3 10 (DEF) Anti-fog system switch
4 11 (A/T) Radiator fan relay
5 12 (MGC) -
6 13 (FAN1) -
7 37 (SPD) Vehicle speed sensor
8 38 (ACSW) -
9 39 (BLW) Heater fan switch
10 40 (STP) Stop light switch
11 41 (AUX) Resistance for switching constant value
12 42 (FAN2) -
13 69 (SEL2) -
14 70 (SEL1) -
15 /1 (H/L) -
16 /2 (ACEV) -
17 73 (0X3) Rear oxygen sensor
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CONNECTOR D (CONNECTED TO THE VEHICLE ELECTRICAL SYSTEM )
1 1 (BAT) Memory protection power supply
2 2 (FC1) -
3 3 (W) Malfunction indicator light
4 4 (ATTX) -
5 b (SI02) -
6 6 (TRRQ) Headlight switch
7 7 (+B1) Fuel supply
8 29 (E21) Rear oxygen sensor ground
9 30 (FC2) Fuel pump relay (without IMB)
10 31 (REV) Engine revs signal (rpm)
11 32 (ATRX) -
12 33 (ATNE) -
13 34 (VF) VF monitor terminal
14 35 (FPOF) -
16 62 (VCO) -
17 63 (VTHO) -
18 64 (IDLO) -
19 65 (FCO) -
20 66 (TRPR) -
21 67 (ACT) -
22 68 (STA) Starter motor signal
Model EURO 4
IS - 393
DRACO CONNECTOR - 14 PIN
1 70 (SEL1) -
2 37 (SPD) Vehicle speed sensor
3 6 (TRRQ) Headlight switch
5 31 (REV) Engine revs signal (rpm)
6 29 (E21) Rear oxygen sensor ground
7 1 (BAT) Memory protection power supply
8 9 (T) Test terminal
9 8 (SI01) Diagnostic tester
10 68 (STA) Starter motor signal
12 34 (VF) VF monitor terminal
13 30 (FC2) Fuel pump relay (without IMB)
14 3 (W) Malfunction indicator light
IS - 394
1 75 (OX1) Front oxygen sensor
2 15 (PIM) Pressure sensor signal
3 14 (ICMB) Ignition unit (with ionic current measurement)
4 73 (OX3) Rear oxygen sensor
5 40 (STP) Stop light switch
6 39 (BLW) Heater fan switch
7 45 (THW) Engine coolant temperature sensor
8 44 (VTH) Throttle valve sensor
9 43 (IE) Ionic current sensor ground
10 80 (VSV1) EGR solenoid valve
11 41 (AUX) Resistance for constant value interruption
12 11 (A/T) Radiator fan relay
13 10 (DEF) Defroster switch
IS - 395
1 27 (#10) Injector (Cyl. 1)
2 58 (IG3) Injection signal (Cyl. 3)
6 82 (GND) Ground lead (-)
7 52 (N2-) Cam angle sensor (-)
8 47 (E2PM) Pressure sensor ground
9 46 (VCPM) Pressure sensor power supply
10 76 (THA) Air intake temperature sensor
11 26 (#20) Injector (Cyl. 2)
12 25 (#30) Injector (Cyl. 3)
13 24 (#40) Injector (Cyl. 4)
14 23 (E1) Signs of ground
15 56 (VSV2) IDLE-UP solenoid valve
16 22 (N2+) Cam angle sensor (+)
17 50 (OXH2) Rear oxygen thermal sensor
18 79 (PRG) PURGE CONTROL solenoid valve
19 20 (OXH1) Front oxygen thermal sensor
20 17 (E2) Ground GND
21 16 (VC) Throttle position sensor power supply
IS - 396
4 PIN DRACO PROGRAM. CONNECTOR
1 82 (GND) Ground lead (-)
2 2d (TX) Signal transmission
3 3d (RX) Signal reception
4 4d (V dc-Ref) (+5 V) Power supply with reference direct current volt-
age
Misure di sicurezza per la diagnosi
SAFETY MEASURES TO REPAIR THE SUPPLY SYSTEM
1. Before carrying out any intervention on the supply system, disconnect the battery negative (-) cable.
2. Do not smoke during the interventions on the supply system. Besides, do not carry out any operation
with open fire.
3. Also with the engine off, the supply duct (between the fuel pump and the fuel delivery pipe) is still
under pressure. Before loosening or removing the pipes, release the fuel pressure according to the
"procedure to release fuel pressure". Also after releasing pressure, a small fuel leak can be detected
when pipes are removed. Therefore, before removal, it is recommended to cover with a cloth the part
to be removed to avoid fuel spraying.
4. The connection method of fuel pipes or vapour emission pipes is different depending on the pipe
type. When fuel pipes or vapour emission pipes are refitted, carry out the connections adequately and
lock the pipes referring to the figure on the side. Check there is no twisting or signs of wear after carrying
out the connection.
IS - 397
Fuel pipe
Pipe insertion length
Insert the pipe so that L1 is at 0 - 2 mm
Clip position.
Fix it so that L2 is at 2 - 5 mm (the clip must not be
placed on the pipe elbow. Besides, it must not ex-
ceed the pipe end).
Suction pipe
Insert the pipe as shown in the figure on the side.
Clip position
The clip end must be at a 2 mm distance from the
pipe end.
KEY:
A= Elbow starting point
IS - 398
Bleeding pipe
Insert the pipe so that L1 is at 0 - 3 mm
Clip position
Lock the pipe so that L2 is at 2 - 7 mm
LEGEND:
A= Elbow starting point
5. When fitting the union bolt on the fuel filter, use a new gasket and tighten to the prescribed torque.
6. When fitting the injector, fuel pipe, fuel pressure regulator or the pulsation damper, fit a new O-ring
or gasket. Before fitting, wet the O-ring with petrol or silicon oil.
Fuel pressure release
1. Set the gearshift lever to the "N" position.
Pull the handbrake and apply locking wedges to the wheels.
2. Remove the upper and lower covers of the steering column.
3. Remove the relay block with the cable harness.
4. Remove fuel pump relay B from the relay block.
5. Start the engine. Run the engine until running out of fuel.
6. Fit the fuel pump relay. Fit the relay block on the body.
CAUTION
- NEVER CARRY OUT THIS INTERVENTION WITH THE ENGINE STILL HOT. FAILURE TO OB-
SERVE THIS SAFETY MEASURE COULD DAMAGE THE CATALYTIC CONVERTER.
AFTER THE ENGINE IS COLD, RELEASE THE FUEL PRESSURE ACCORDING TO THE PROCE-
DURE DESCRIBED BELOW.
WARNING
- BE EXTREMELY CAREFUL SO AS NOT TO ENTANGLE THE WIRE WHILE THE RELAY BLOCK
IS FITTED.
IS - 399
7. Fit the upper and lower covers of the steering
column.
N.B.
- IF THE DIAGNOSTIC TESTER DS - 21 IS USED, SELECT
" FUEL PUMP LOCKED" IN THE " ACTUATOR CONTROL"
WHILE THE ENGINE IS RUNNING, AND CONTINUE RUN-
NING THE ENGINE UNTIL THIS LOCKS.
Fuel leak check
After repairing the supply system, carry out the following checks to verify there are no fuel leaks.
1. Set the ignition switch to ON for three seconds, then put it back to OFF. Repeat the operation three
or four times.
2. Now, check there are no leaks in the supply system.
Troubleshooting safety measures
1. Never disconnect the connector from the electronic control unit, the battery cable, the ground lead
of the electronic control unit from the engine, or the main fuse, before the diagnosis information stored
in the memory of the electronic control unit is confirmed.
2. The diagnosis information stored in the memory of the electronic control unit can be cleared with the
diagnostic tester DS-21 or OBD-II general scanning device in the same way control is. Therefore, before
using the tester, read the relevant user manual so as to understand the operation perfectly.
3. Troubleshooting priority. A priority is specified for troubleshooting a certain number of diagnosis
codes in the relevant operation diagram, act observing such priority. If it is not specified, comply with
the priority indicated below and carry out troubleshooting for each code.
failure code different from P0171, P0172 (too lean/too rich in the supply system), and P0300,
P0301-P0304, P0314 (irregular ignition).
P0171, P0172 (too lean/too rich in the supply system).
P0300, P0301-P0304, P0314 (irregular ignition).
4. Before carrying out checks, read the section "system circuit checking safety measures" carefully.
Carry out the diagnosis being extremely careful where necessary.
Diagnosi del motore
General information
The engine and the engine control system of this vehicle are controlled by the electronic control system.
Besides, the vehicle is also equipped with an on board diagnosis system. If failures are detected in the
input/output systems (sensors, actuators, cable harnesses, connectors, etc.) of the engine control sys-
tem, the electronic control unit stores the relevant failure and informs the rider with the relevant
malfunction indicator light turning on or flashing (MIL, warning light). Besides, the operator is informed
IS - 400
about the failure by means of the data link connector (diagnosis connector). While engine failures are
identified, it is necessary to have a general idea of the on board diagnostic system as well as a perfect
knowledge of the safety measures to be observed during troubleshooting, and how to use a tester.
Therefore, carry out troubleshooting according to the operation diagram which specifies the correct
procedure to be followed.
European on board diagnostic system of vehi-
cles (EOBD)
The vehicles designed for the European market
are equipped with the following functions, comply-
ing with the standard 1999/102/EC (generally
called EURO-OBD)
1. With the ignition switch set to ON, the warning
light (MIL) turns on. If no operation failure is de-
tected, the warning light turns on, once the engine
is started (check if the bulbs are burnt).
2. If during the engine operation, the electronic control unit detects an operation failure in the emission
control system/components (which could negatively affect emissions), or in propeller control compo-
nents, or a failure is detected in the same control unit, the warning light turns on or flashes (only if an
irregular ignition which can damage the catalytic converter is detected). Therefore, the electronic control
unit stores the area that has an operation failure (failure code ISO 15031-6/SAEJ 2012). If the failure is
not detected for three sequential times, the warning light turns on automatically. In any case, the failure
code is stored in the electronic control unit memory.
N.B.
- THE WARNING LIGHT TURNS ON ONLY IN CASE OF FAILURES AFFECTING VEHICLE EMIS-
SIONS
for example:
Diagnostic failure code P0105
Failure detected: Intake air absolute pressure failure / barometric pressure circuit failure
Diagnostic failure code: P0110
Failure detected: Intake air temperature circuit failure
Failure detected: Engine coolant temperature circuit failure
Failure detected: Circuit failure: engine coolant temperature/functional problems
IS - 401
Failure detected: Throttle valve position sensor Failure (TPS) / pedal position sensor / switch "A"
3. It is possible to read different data sent by the
electronic control unit connecting the OBD II gen-
eral scanning device complying with the format
specified by ISO 14230, or the diagnostic tester
DS-21 to the data link connector of the vehicle.
Troubleshooting can be performed efficiently by
controlling these data (failure code, frozen image
data, current data, oxygen sensor monitor data,
etc.).
4. The failure code is formed by the ISO standard
code (specified by ISO 15031-6) and by designa-
tion code of the manufacturer. The ISO standard
code must be set complying with the ISO stand-
ards. On the other hand, the manufacturer desig-
nation code can be freely set by the manufacturer
within a specified limit.
ISO Diagnosis Code Key
1. B: Body C: Chassis P: Propulsor U: Network
2. 0: Regulation 1: Maker
3. Vehicle system
4. Diagnostic failure code digits for example: 1 & 2 : Fuel and air measurement 3 : Ignition
system 7 & 8 : Transmission
5. Many failure codes have a detection logic with two interventions, which avoids the incorrect detection
and which starts working only when there has been an operation failure undoubtedly. Nevertheless,
another mode of diagnosis is determined, for which a single final confirmation test is necessary, so that
the mechanic confirms that the operation failure has been completely removed after the repair. This
mode can be activated with the OBD II general scanning device or with the diagnostic tester DS-21. If
the diagnostic tester DS-21 is used, select "continuous monitoring results" of "vehicle communication
in CARB mode".
Failure detected: Oxygen sensor heater circuit failure
Failure detected: Fuel trim system too lean
IS - 402
Failure detected: Fuel trim system too rich
6. When an operation failure is detected, the en-
gine running conditions at the moment the failure
is detected are stored as frozen image data in the
memory of the electronic control unit .
7. Detection logic with 2 interventions.
When an operation failure is detected for the first
time, such failure is temporarily stored in the mem-
ory of the electronic control unit (first operation). If
this failure is detected again during the second op-
eration, the warning light turns on and the failure
code is determined (second operation). (The igni-
tion switch must be always off between the first
and the second operation).
8. Frozen image data
When an operation failure is detected for the first
time, the engine running conditions at the moment
the failure is detected are stored in the memory.
The engine status and running conditions are stor-
ed when the operation failure is detected (supply
system, calculated load, engine coolant tempera-
ture, fuel trim, engine speed, vehicle speed, etc.).
The frozen image data are therefore useful for
troubleshooting and for determining if the vehicle
was running or stopped, if the engine was hot or
not, if the air - fuel ratio was lean or rich, when the
operation failure was detected
9. Frozen image data update
Considering that the electronic control unit can store the frozen image data for each single malfunction,
the data described in point 1 have priority when the data are stored. If the data described in point 1 are
detected when the data described in point 2 are already stored, the data 2 are replaced by data 1.
1: Frozen image data the first time the operation failure is detected between the irregular ignition (P0300-
P0304 e P0314), supply system too lean (P0171) and supply system too rich (P0172).
2: Frozen image data when an operation failure different from the one specified in point 1 is detected.
IS - 403
- If the operation failure detected afterwards has a
lower priority or the same priority than the previous
one, data are not updated.
10. Clearing the frozen image data. The frozen im-
age data are cleared at the same time the failure
code is cleared. Except for vehicles equipped with
electrically controlled automatic transmission, the
frozen image data can be cleared at the same time
the failure code is cleared selecting the option
"failure code clearing (others)".
Misure di sicurezza per la diagnosi
Data link connector (common destinations)
The vehicle engine electronic control unit adopts
the ISO 14230 protocol (Euro-OBD). As regards
the position, shape of the connector and pin layout,
the data link connector complies with the stand-
ards ISO 15031-3 (SAEJ 1962) and the format ISO
14230. The OBD II serial data line (ISO 14230 K
line) is used for the OBD II general scanning de-
vice or for the diagnostic tester DS-21, to allow
communication with the electronic control unit.
DLC CONNECTOR KEY
16 Battery powered
13 ECU - T
12 EFI - T
9 REV - Engine revs signal
7 OBD II serial data line (ISO 14230 K line)
Present during transmission
5 ECU ground
4 Chassis ground
N.B.
WITH THE CABLE OF THE DIAGNOSTIC TESTER DS-21 CONNECTED TO THE DATA LINK CON-
NECTOR BY MEANS OF THE CONTROL UNIT SELF-DIAGNOSIS CONTROL CABLE HARNESS,
SET THE IGNITION SWITCH TO ON. IF THE TESTER VOLTAGE INDICATOR DOES NOT TURN
ON, PERFORM THE FOLLOWING CHECKS AND REPAIR THE PARTS NOT WORKING PROPER-
LY.
IS - 404
Specific tooling
A =voltage indicator (switch section)
CONNECT THE TESTER DS-21 TO ANOTHER VEHICLE, SET THE IGNITION SWITCH TO ON:
1. When the voltage indicator of the diagnostic tester DS-21 turns on: Vehicle side operation failure.
Check the data link connector, +B and Ground. - BAT terminal voltage check - Continuity check
between terminals E and Ground.
2. When the voltage indicator of the diagnostic tester DS-21 does not turn on: Operation failure of the
diagnostic tester DS-21
Troubleshooting
The engine control system is equipped with diagnosis functions able to diagnose areas which have
operation failures. Such functions are important for troubleshooting purposes. The operation diagram
in the following page shows the procedure to be followed to identify the failures using the diagnosis
functions mentioned. The operation diagram shows how to use the diagnostic failure code control effi-
ciently. Besides, once all the results are examined, it can be determined if the troubleshooting is carried
out according to the diagnostic failure codes or according to the malfunction phenomenon. The diag-
nosis of this system is equipped with a battery protection function (which allows to power the diagnosis
memory also with the ignition switch set to OFF).
- IF THE DIAGNOSTIC TESTER DS-21 OR OBD-II GENERAL SCANNING DEVICE IS NOT USED,
THE DIAGNOSTIC FAILURE CODE OR THE FROZEN IMAGE DATA CAN NOT BE READ IN THE
OPERATION DIAGRAM.
Customer information
The cause of the vehicle failure can not be removed, if the malfunction phenomenon is not previously
confirmed. Even if operations are continued for a long indefinite time, the vehicle can not be restored
unless the malfunction phenomenon is confirmed. The information provided by the customer is impor-
tant and it must be obtained even before the malfunction phenomenon confirmation. The information
obtained from the customer is important evidence to reproduce the malfunction phenomenon. Besides,
information provided by the customer can be consulted during troubleshooting. Therefore, instead of
posing general questions, focus attention on what is related to the defect. The following five points
represent the most important questions to be posed to analyse the operation defect. In some cases,
information about defects previously detected and about the past record of repairs, which apparently
IS - 405
have nothing to do with the current defect, could instead turn out useful to repair the defect. It is therefore
important to manage to obtain as much information as possible and bear it in mind as a reference during
the identification of the malfunction phenomenon.
Main points to analyse the defect the customer has complained about
What? Vehicle model, system rules
When? Date, time, event frequency
Where? Road surface conditions
Under which conditions? Running conditions, riding conditions, atmospheric con-
ditions
What happened? How could the customer identify the operation defect?
Question form
If the question form is prepared beforehand, as
shown below, it is possible to pose all the neces-
sary questions. A standard form which can be
modified according to the single characteristics of
the market is shown below.
Question form
Checking, storing and clearing the failure code/frozen image data
Once the failure code is indicated, confirm if that particular defect has been previously detected or if it
is still being detected currently, and confirm how the defect is related to the failure reproduced. To
confirm this, indicate the failure code / frozen image data twice, that is to say, indicate the failure code /
frozen image data, clear the data, and confirm the malfunction phenomenon. Then, indicate the failure
code / frozen image data once more.
It is recommended to check the failure code (including the failure codes which are not identified) referring
to the section "failure code checking procedure". Print or take note of the code and frozen image data
when they are identified. Then, clear them referring to the "failure code clearing" procedure. If the failure
code is not cleared, an incorrect diagnosis could be carried out, reaching the conclusion that the regular
circuit is not working properly, or difficulties could arise during troubleshooting.
Malfunction phenomenon reproduction confirmation
While identifying failures, the operator can not detect the cause of the malfunction unless the phenom-
enon is confirmed. In this regard, it is essential to reproduce the failure phenomenon recreating the
same conditions and environment where the failure was detected, according to the information obtained
from the customer.
In case of phenomena which can not be easily reproduced, recreate the same running conditions oc-
curring when the failure was detected (road surface conditions, atmospheric conditions, riding condi-
tions). To that end, it is very important to try to reproduce the failure constantly, with the aid of external
IS - 406
factors such as movements (moving the wires and the relay manually), heat (using hot air), and water
(humidity).
Movements, heat or humidity can be the failure causes which are difficult to be reproduced. Therefore,
with the vehicle stopped, the failure reproduction simulation test described below can be performed.
Besides, if it is considered that a component causes the failure and a tester, etc. is connected to that
component so as to confirm the failure phenomenon, it is also possible to assess functionality.
Counterchecking, storing and clearing the failure code/frozen image data
By checking the failure code/frozen image data after having confirmed the malfunction phenomenon
reproduction, it can be determined if the system indicated by the failure code before the reproduction
confirmation works properly or not. Afterwards, proceed with one of the following steps.
1. When a failure code is detected at the moment of checking, and this code is detected after the
malfunction reproduction confirmation, it means that the problem still remains in the diagnosis circuit.
Remove failures according to the codes detected.
2. If no abnormal code is detected, although the failure has been found during the malfunction repro-
duction confirmation, it is probable that a different defect from the one connected to the diagnosis system
is being detected. Remove the failure according to the malfunction phenomenon.
3. If no malfunction is detected during the malfunction reproduction confirmation, and the regular code
is indicated when the failure code is checked, it is assumed that an abnormal situation, as bad contacts
of cables and connectors was previously detected, but it does no longer exist currently. Check cables
and connectors of the system connected to the failure code detected before the malfunction phenom-
enon reproduction confirmation.
Visual check
Check cables and connectors of the systems indicated at the moment of the initial check of the failure
code, according to the "visual check and contact pressure check" procedure.
Check and repair according to the table of self-diagnosis codes
Before troubleshooting, perform the basic check to identify the possible malfunction causes. For ex-
ample, if by checking the spark, it turns out that there are no problems, it can be inferred that the ignition
system works properly. Besides, the defect causes can be identified also according to the information
obtained from the customer
N.B.
- IF THE MALFUNCTION CAN NOT BE DETECTED THROUGH THE DIAGNOSIS SYSTEM, AL-
THOUGH THERE IS A MALFUNCTION PHENOMENON, IT MEANS THAT SUCH DEFECT IS NOT
INCLUDED WITHIN THE DETECTION RANGE OF THE DIAGNOSIS SYSTEM OR THAT THE DE-
FECT IS IN A SYSTEM DIFFERENT FROM THOSE CONNECTED TO THE DIAGNOSIS SYSTEM.
Checking malfunctions which are detected intermittently
Inspect the parts where the malfunction is detected intermittently, as cable harness and connectors, as
described in the section "Checking malfunctions which are detected intermittently and bad contacts".
During the inspection, focus checks on the circuits connected to the failure code systems indicated at
the moment of the failure code initial check
IS - 407
Final confirmation test
Confirm that the malfunction phenomenon detec-
ted by the customer has been completely re-
moved. If parts repaired are connected to the code
failure, clear the code one time and perform the
failure code confirmation test. Check that no code
is indicated. Now, to increase the operation effec-
tiveness, make use of the function "continuous
monitoring results" (if the diagnostic tester DS-21
is used, select the option "continuous monitoring
results" from the CARB mode vehicle communi-
cation menu).
Malfunction reproduction simulation test
1. Vibration:
When vibration is considered the main cause
Connector
Slightly shake the connector vertically or laterally
Cables
Slightly shake the cables vertically and laterally
The points to be checked are the connector join
points, vibration points and the section in which the
cables pass through the body.
IS - 408
Parts, sensors
With the finger, slightly move the part of the sensor
which is considered the cause of the malfunction.
Check if the malfunction is reproduced.
N.B.
- PAY ATTENTION NOT TO MOVE THE RELAY EXCES-
SIVELY, SINCE IT COULD DAMAGE THE REMOTE CON-
TROL.
2. Cold/hot:
In case of a part which is considered the cause of
the failure when it is hot and cold. Heat the com-
ponent which is suspected to be the cause of the
failure with a hair dryer or a similar device. Check
if a malfunction is detected.
CAUTION
- DO NOT EXCEED A TEMPERATURE OF 60C. (MAXIMUM
LIMIT TO AVOID DAMAGING THE COMPONENT).
- DO NOT HEAT THE PARTS DIRECTLY IN THE ELEC-
TRONIC CONTROL UNIT.
3. Water application:
If it is suspected that the malfunction is detected
during rainy days or in humid conditions.
Wet the vehicle with water. Check if a malfunction
is detected.
N.B.
- NEVER WET THE ENGINE COMPARTMENT DIRECTLY.
THE TEMPERATURE AND HUMIDITY CAN BE CHANGED
BY WETTING THE RADIATOR FRONT PART INDIRECTLY.
- NEVER WET THE ELECTRONIC PARTS.
- IF CASE OF RAIN INFILTRATION TO THE VEHICLE IN-
SIDE, THE WATER COULD PENETRATE INSIDE THE
ELECTRONIC CONTROL UNIT THROUGH THE CABLES. IF
PREVIOUS WATER INFILTRATION ARE DETECTED, BE
EXTREMELY CAREFUL.
4. Another:
When it is considered that the malfunction is de-
tected by applying a heavy electric charge.
Activate all the electrical charges, including the
heater fan, lights, anti-fog system rear window,
etc. Check if a malfunction is detected.
IS - 409
Procedura ricerca guasti
Checking diagram common options
1. For a correct troubleshooting, refer to the checking procedure detailed for each circuit according to
the failure code diagram or the diagram related to malfunction phenomena.
2. If by troubleshooting of all the components, wires and connectors, except for the electronic control
unit, no malfunction is detected, it is probable that the electronic control unit is not working properly.
Therefore, if no defect is detected after the diagnosis, check the electronic control unit and replace it,
if necessary, also if no problem has been found in it. Check if a malfunction phenomenon has been
detected. If there are no malfunction problems, proceed with checks according to the method of the
malfunction reproduction simulation test.
3. Checking procedures on cable harnesses, electrical and electronic components described in this
chapter can be applied to various systems. Checks must be therefore performed according to these
procedures, as described below.
4. To test the cable harness between the EFI ECU control unit and the DRACO Emission Control Unit,
disconnect the latter from the DRACO and from the EFI ECU and connect the SST on the EFI side.
Then check for open circuits or short circuits with a multimeter, referring to the DRACO pin-out table
(EFI ECU side).
Checking wires and connectors
Wire and connector malfunctions are caused by
interrupted or short-circuited wires.
Interrupted wire:
it is caused by detached wires, bad contacts inside
the connector, disconnected connector terminal,
and so on.
- There are bad contacts due to the formation of
oxide on the connector terminal, foreign bodies on
the terminal, or inadequate contact pressure be-
tween the male and female terminals of the con-
nector. Simply disconnect the connector one time,
then connect it again. The contact could be in this
way modified, restoring regular operation. If during
checking no defect is detected in wires and con-
nectors, and if the malfunction stops after finishing
checks, it is probable that the wire or the connector
could be the cause of the problem.
N.B.
- WIRES ARE RARELY CUT AT THE CENTRE. IN MOST OF
THE CASES, THERE IS AN INTERRUPTED WIRE NEARBY
IS - 410
CONNECTORS. CHECK VERY CAREFULLY THE CONNEC-
TORS OF THE SENSOR AND THE ACTUATOR
Short circuit:
this is caused by a short circuit between the cable
harness and the chassis ground, or by a short cir-
cuit inside the switches, etc.
- IF A SHORT CIRCUIT IS DETECTED BETWEEN THE CA-
BLE HARNESS AND THE CHASSIS GROUND, CHECK IF
THE WIRES ARE ENTANGLED, IF THE WIRE IS RUBBED,
IF THE INSULATING PART IS BROKEN ALLOWING A CON-
TACT WITH OTHER PARTS, AND IF THE WIRE IS LOCKED
PROPERLY.
Resistance check (short circuit check)
1. Disconnect the connector on both sides
2. Measure the resistance between the relevant connector terminals and the chassis ground. Besides,
check connectors on both sides.
- SLIGHTLY SHAKE THE CABLE HARNESS LONGITUDINALLY AS WELL AS HORIZONTALLY
DURING THE MEASUREMENT OF RESISTANCE.
Characteristic
Resistance:
10 M or more
Continuity check (interrupted wire check)
1. Disconnect the connector on both sides of the
electronic control unit and the sensor
2. Measure resistance between the connector ter-
minals
- SLIGHTLY SHAKE THE CABLE HARNESS LONGITUDI-
NALLY AS WELL AS HORIZONTALLY DURING THE MEAS-
UREMENT OF RESISTANCE.
Characteristic
Resistance:
10 or less
IS - 411
In case of waterproof connectors, probes A must
be inserted in the connector on each cable har-
ness side.
- If the waterproof connector is checked without
removing waterproof rubber, be careful not to de-
form the connector terminal during the probe ap-
plication.
Visual inspection and contact pressure check
1. Disconnect the connectors on both sides of the
relevant cable harness.
2. Visually inspect for rust on the connector termi-
nal. Besides, check that there are no foreign bod-
ies.
3. Check that the tightened section A is not loos-
ened or damaged. Besides, check that the termi-
nal is not disconnected slightly pulling the connec-
tor wire.
4. Prepare this male terminal of the connector ter-
minal. Insert it in the female terminal and slightly
pull to check the socket. If the socket force is lower
with respect to that one of the other terminals, the
contact could result bad.
- IF THERE IS RUST ON THE TERMINAL OR FOREIGN
BODIES ARE FILTERED, OR IF THE CONTACT PRESSURE
BETWEEN THE MALE AND FEMALE TERMINAL DECREA-
SES, DISCONNECT AND CONNECT THE CONNECTOR
AGAIN SO THAT A MALFUNCTION IS NOT DETECTED. IF
CABLE HARNESS AND CONNECTOR CHECK DOES NOT
SHOW FAILURES, THE MALFUNCTION CODE IS CON-
FIRMED. NOW, IF NO MALFUNCTION PHENOMENON IS
REPRODUCED, IT IS PROBABLE THAT DEFECT WAS
IS - 412
CAUSED BY A BAD CONTACT BETWEEN THE MALE AND
THE FEMALE TERMINAL.
Check the malfunction which is detected intermittently and false contacts
The relay or solenoid valve can be locked. Most of the operation defects which are detected intermit-
tently are due to interrupted wires caused by bad connections or wrong connections inside the circuit.
Check, following the described procedure.
1. Inspect the connector and the terminal. Check according the options related to interrupted wires in
the section "cable harness and connector check".
2. Visual inspection and check of the contact pressure. Check according to options indicated in point
"Visual Inspection and contact pressure check ".
3. inspect the DRACO control unit, checking continuity between the pin of the vehicle device cable
harness side and those of the EFI ECU interface side, or checking for possible internal short circuits.
As an extra check, it is possible to bypass the DRACO connecting the cable harness of vehicle devices
to EFI ECU control unit.
Checking and replacing the electronic control
unit
First of all, check the ground circuit of the elec-
tronic control unit. If an operation defect is detec-
ted, repair the ground circuit. If no defect is
detected, replace the electronic control unit.
1. Disconnect the electronic control unit connector.
Inspect that there is no bending on ground termi-
nals E1 and E2 on the electronic control unit side
and on the cable harness side. Also check the
contact pressure.
2. Measure the resistance between ground termi-
nals E1 and E2 (cable harness side) and the chas-
sis ground. In addition, measure the voltage
between the power supply terminal (cable harness
side) and the chassis ground.
- WHEN THE GROUND CIRCUIT OF THE ELECTRONIC
CONTROL UNIT IS CHECKED, IT CAN BE THE CASE IN
WHICH THE TERMINAL CONTACT CONDITIONS CAN BE
MODIFIED BY DISCONNECTING AND CONNECTING THE
NEW CONNECTOR AND RESULTING IN " NO OPERATION
DEFECTS" . IF WHILE CHECKING THE GROUND CIRCUIT
OF THE ELECTRONIC CONTROL UNIT NO MALFUNC-
TIONS ARE DETECTED, CONNECT THE NEW ELECTRON-
IC UNIT CONNECTOR TO CONFIRM THAT THE THERE IS
A MALFUNCTION. NOW, IT CAN BE DETERMINED IF THE
CONTROL UNIT IS DEFECTIVE.
IS - 413
Characteristic
Resistance:
10 . or less
Voltage:
battery voltage
Codici diagnotici
Failure code diagram specifications
SPECIFIED CODES OF THE ISO/SAE STANDARDS
For further information related to single codes, refer to the failure code diagram.
Failure detected:Manifold absolute pressure/ barometric pressure circuit malfunction
Affected area
- Interrupted or short-circuited cable in the manifold absolute pressure sensor
- Manifold absolute pressure sensor
- Engine electronic control unit (ECU)
Failure detected:Intake air temperature circuit failure
Affected area
- Interrupted or short-circuited cable in the intake air temperature sensor
- Intake air temperature sensor
- Engine electronic control unit
Failure detected:Engine coolant temperature circuit failure
Affected area
- Interrupted or short-circuited cable in the water temperature sensor circuit
Failure detected: Engine coolant temperature/functional problems
Affected area
- Cooling system
Failure detected:Throttle switch circuit/pedal position sensor/switch "A" failure
Affected area
- Interrupted or short-circuited wire in the throttle position sensor circuit
- Throttle position sensor
IS - 414
Failure detected:Oxygen sensor circuit failure (bank 1, sensor 1)
Affected area
- Air intake system
- Fuel pressure or Injector
- Interrupted or short-circuited cable in the front oxygen sensor Heater circuit (O1).
- Oxygen sensor heater
Failure detected:Oxygen sensor circuit slow response (bank 1, sensor 1)
Affected area
- Air intake system
- Fuel pressure
- Injector injection
- Interrupted or short-circuited cable in the oxygen sensor heater circuit.
- Engine electronic control unit (ECU)
Failure detected:Oxygen sensor heater circuit failure (bank 1, sensor 1)
Affected area
- Interrupted or short-circuited cable in the oxygen sensor circuit heater.
Failure detected:Rear oxygen sensor circuit failure (O2) (bank 1, sensor 2)
Affected area
- Interrupted or short-circuited wire in the rear oxygen sensor circuit heater (O1).
- Rear oxygen sensor (O2)
Failure detected:Oxygen sensor heater circuit failure (bank 1, sensor 2)
Affected area
- As failure code P0135
Failure detected:Fuel trim system too lean (lean air-fuel ratio failure, bank 1)
Affected area
- Air intake (pipe loosened)
- Fuel duct pressure
IS - 415
- Injector locking or leakage
- Interrupted or short-circuited wire in the oxygen sensor circuit.
- Oxygen sensor
- Gas leak in the exhaust system
- Vacuum switching valve for vapour bleeding
Failure detected:Fuel trim system too rich (lean air-fuel ratio failure, bank 1)
Affected area
- Interrupted or short-circuited wire in the oxygen sensor circuit.
- Oxygen sensor
- Vacuum switching valve for vapour bleeding
Failure detected:Random/multiple cylinder irregular ignition
Affected area
- Ignition system
- Injector
- Fuel pressure
- Compression pressure
- Adjustment valve clearance of valves
- Ionic current sensor
- Interrupted or short-circuited wire in the engine wires
- Connector connection
Diagnostic failure code: P0301 P0302 P0303 P0304
Failure detected: Irregular ignition
- Cylinder 1
IS - 416
- Cylinder 2
- Cylinder 3
- Cylinder 4
Affected area:
- Ignition system
- Injector
- Fuel pressure
- Adjustment valve clearance of valves
- Ionic current sensor
Failure detected: Single cylinder irregular ignition (cylinder not specified) (EU standards)
Affected area:
- Interrupted or short-circuited wire in the engine wires
Failure detected: Crankshaft position sensor circuit "A" failure
Affected area:
- Interrupted or short-circuited wire in the cam angle sensor circuit
- Cam angle position sensor
- Rotor signal
Failure detected: Catalytic converter efficiency below the threshold limit
Affected area:
- Three-way catalytic converter
- Interrupted or short-circuited wire in the oxygen sensor circuit (heated).
- Oxygen sensor (heated)
Failure detected: Vapour emission control system - bleeding control valve failure
Affected area:
- Interrupted or short-circuited wire in the vapour vacuum switching valve circuit
- Vacuum switching valve for vapours
IS - 417
Failure detected: Vehicle speed sensor failure
Affected area:
- Interrupted or short-circuited wire in the vehicle speed sensor circuit.
- Instrument panel
- Vehicle speed sensor
DAIHATSU MOTOR CORPORATION CODES
Failure detected: Barometric pressure sensor circuit failure
Affected area:
Failure detected: Ionic system failure
Affected area:
- Interrupted or short-circuited wire in the ionic system circuit.
- Ignition unit
- Ignition coil (all cylinders)
- Spark plug (all cylinders)
Failure detected: Start-up signal circuit failure
Affected area:
- Interrupted wire in the start-up signal circuit
Failure detected: Switch signal circuit failure
Affected area:
- Interrupted or short-circuited wire in the C/A switch circuit
- C/A switch
- Interrupted or short-circuited wire in the throttle valve sensor circuit
- Throttle valve sensor
- Interrupted or short-circuited wire in the neutral starter switch
- Neutral starter switch
Failure detected: Electronic control unit protection power supply circuit failure
Affected area:
- Interrupted wire in the electronic control unit protection power supply circuit
IS - 418
Failure detected: Exhaust gas recirculation system control valve circuit failure
Affected area:
- Interrupted or short-circuited wire in the circuit of the vacuum switching valve for EGR
- Vacuum switching valve for EGR
FAILURE-FREE FUNCTION
If one of the following codes are detected, the electronic control unit enters the failure-free mode allowing
the riding of the vehicle with complete safety. If the failure is indicated regularly, the failure-free com-
mand is deactivated. The diagnosis results remain anyway in the memory. It is therefore necessary to
determine if the failure is still there or not.
FAILURE-FREE SPECIFICATIONS
failure codes-1, failure code No. P0105:
Failure detected:When the signal sent by the inlet manifold pressure sensor indicates there is an
interrupted or short-circuited wire.
Failure-free operation:
- The signal sent by the inlet manifold pressure sensor is set to the value established by the throttle
opening angle, engine speed and ISC opening angle
- Ignition timing is set to be controlled according to the pressure determined by the engine speed and
by the above-mentioned value.
- The fuel supply is interrupted if the throttle opening angle and the engine speed exceed the respective
set values.
Failure detected: When the signal sent by the intake air temperature sensor indicates there is an
Interrupted or short-circuited wire.
- The signal sent by the intake air sensor is set to a constant value
Failure detected: When the signal sent by the engine coolant temperature sensor is open or closed.
- The signal of the engine coolant temperature sensor turns into a constant value.
Failure detected:When the signal sent by the throttle position sensor indicates there is an Interrupted
or short-circuited wire.
- The signal sent by the throttle position sensor turns into a constant value.
IS - 419
Failure detected:When an abnormal situation is detected in the signal sent by the rear oxygen sensor
- The rear oxygen sensor return is blocked.
- The correction coefficient of the rear oxygen sensor return is set to the value determined by the engine
speed and by pressure.
Failure detected:When the signal sent by the atmospheric pressure sensor indicates there is an In-
terrupted or short-circuited wire.
- The signal sent by the atmospheric pressure sensor is set to a constant value.
Matrix table for troubleshooting
Matrix table for troubleshooting according to the malfunction phenomenon
If no failure code is detected during the check, and if no defect is confirmed during the basic check,
perform troubleshooting referring to the following table.
Start-up problems
Malfunction phenomenon Probable affected area
The engine does not start with the starter motor
(does not start-up)
Starter motor and starter motor relay
The engine starts normally (difficult start-up) Fuel pump checking circuit
Injector circuit
Ignition coil circuit (with ignition spark plug)
Spark plug
Vacuum switching valve circuit to increase idle speed
An initial combustion is not detected Electronic control unit power supply circuit
Fuel pump checking circuit
Injector circuit
Spark plug
Even if an initial combustion is detected
This is not complete
Injector circuit
Difficult start-up (winter) Fuel pump checking circuit
Injector circuit
Spark plug
IS - 420
Difficult start-up (summer) Fuel pump checking circuit
Injector circuit
Spark plug
Engine does not hold idling
Idle speed not in working order Vacuum switching valve circuit to increase idle speed
Minimum speed too slow Electronic control unit power supply circuit
Injector circuit
Minimum speed too fast Pipe, etc. detached
PVC line
Irregular/unstable idle speed Fuel pump checking circuit
Injector circuit
Fuel duct filter
Oscillation during idle speed operation Electronic control unit power supply circuit
Pipe, etc. detached
PVC line
The engine stops during idle speed operation Fuel pump checking circuit
Injector circuit
Fuel duct filter
Engine irregular performance
The engine stops when the accelerator pedal
is pushed
Fuel filter - Fuel circuit pipes
PVC line
The engine stops when the accelerator pedal
is released
Injector circuit
Oscillation while riding Pipe, etc. detached
IS - 421
PVC line
No output Fuel pump checking circuit
Injector circuit
Engine poor at full power
Hesitation on acceleration phase Fuel pump checking circuit
Injector circuit
Signs of knocking
Head knocking Fuel pump checking circuit
Injector circuit
Backfire/fire retarding Injector circuit
Ignition pump circuit (with ignition spark plug)
Spark plug
Diagnostic Failure Code Clearing
The failure code and frozen image data can be cleared as follows:
1. The diagnostic tester or OBDII general scanning device is used to clear the failure code (refer to the
relevant user manual for the procedure).
2. The electronic control unit power supply is interrupted allowing to clear the failure code without using
the diagnostic tester or OBD II general scanning device. (Disconnect the battery negative (-) terminal
or detach the injection system fuse).
Controlli
Diagnostic failure code check
Before inspecting, check the warning light following the procedure described below.
IS - 422
Warning light check
1. Check if the warning light turns on with the ig-
nition switch set to ON, but with the engine stop-
ped.
2. Check if the warning light turns off when the en-
gine is started.
If the warning light remains on or flashing, the di-
agnosis system has detected an operation defect.
A failure code has been therefore stored in the
electronic control unit.
If no failure code has been stored in the electronic
control unit, check the warning light circuit.
N.B.
- IF THE WARNING LIGHT DOES NOT TURN ON, PERFORM
TROUBLESHOOTING ON THE INSTRUMENT PANEL.
Failure code check using the diagnostic tester
DS-21 or OBD II general scanning device
1. Prepare the diagnostic tester DS-21 or OBD II
general scanning device.
2. With the ignition switch set to OFF, connect the
diagnostic tester DS-21 or OBD II general scan-
ning device to the data link connector located at
the lower part of the driver side instrument panel.
Now, connect the diagnostic tester DS-21 to the
data link connector interposing the following spe-
cial tool, and connect the OBD II general tester
directly.
Specific tooling
IS - 423
3. Set the ignition switch and the tester main switch
to ON.
4. Check the failure code and frozen image data.
Print or take note. (For the operative procedure,
refer to the user manual).
If the OBD II general scanning device is used, only
failure codes determined by ISO/SAE can be read.
However, DMC failure codes can not be read.
(1) As regards the failure check with 2 interven-
tions (failure code detected only once) not identi-
fied, select the option "continuous monitoring
results" from the menu "vehicle communication" of
the CARB mode, and press the "F1 " key. The
possible failure codes detected are properly indi-
cated.
(2) Also in this case, the OBD II general scanning
device indicates only the failure codes specified by
the ISO/SAE standards. DMC failure codes can
not be read.
5. Once checking has finished, set the tester main
switch and the ignition switch to OFF. Disconnect
the special tool from the data link connector, then
disconnect the tester from the special tool.
N.B.
- IF THE MALFUNCTION PHENOMENA MUST BE REPRO-
DUCED WITH THE DIAGNOSTIC TESTER DS-21 OR OBD II
GENERAL SCANNING DEVICE CONNECTED TO THE DA-
TA LINK CONNECTOR, THE FUNCTION " CONTINUOUS
MONITORING RESULTS" CAN BE USED (IF THE DIAG-
NOSTIC TESTER DS-21 IS USED, SELECT THE OPTION
" CONTINUOUS MONITORING RESULTS" FROM THE
MENU " VEHICLE COMMUNICATION" OF THE CARB
MODE). WITH THIS FUNCTION, THE FAILURE CODE CAN
BE INDICATED WHEN THE MALFUNCTION PHENOMEN-
ON IS REPRODUCED. (REQUEST FOR ON BOARD MONI-
TORING TEST RESULTS ISO 15031-5, CONTINUOUS
MONITORING SYSTEM).
Diagnostic failure code clearing
The failure code and frozen image data can be cleared as follows:
IS - 424
1. The diagnostic tester DS-21 or OBDII general scanning device is used to clear the failure code (refer
to the relevant user manual for the procedure).
2. The electronic control unit power supply is interrupted allowing to clear the failure code without using
the diagnostic tester DS-21 or OBD II general scanning device. (Disconnect the battery negative (-)
terminal or detach the injection system fuse).
Using the diagnostic tester DS-21 or OBD II
general scanning device
1. As in failure code checking, connect the diag-
nostic tester DS-21 to the data link connector in-
terposing the following special tool. Or, connect
the OBD II general scanning device directly.
Specific tooling
2. Set the ignition switch and then the tester main
switch to ON.
3. If the diagnostic tester DS-21 is used, clear the
failure code by selecting the option "Failure code
clearing (others)" from the menu "Vehicle commu-
nication" of the DAIHATSU mode.
4. After clearing the code, set the tester main
switch and the ignition switch to OFF. Disconnect
the special tool from the data link connector and
disconnect the diagnostic tester DS-21 from the
special tool. Or, disconnect the OBD II general
scanning device.
The diagnostic tester DS-21 is not used
When the diagnostic tester DS-21 or OBD II
general scanning device is not used:
Clearing by disconnecting the injection system
fuse. To clear the diagnostic failure codes stored
in the control unit after the malfunction has been
repaired, disconnect the injection system fuse
from the relay block for at least 30 seconds with
the ignition switch set to OFF. With an ambient
temperature of about 20C
IS - 425
- Warming up cycle
The warming up cycle refers to the riding cycle
which allows to increase water temperature to at
least 22C above the temperature at the moment
of the engine start-up, reaching at least 70C.
- Riding cycle
The riding cycle comprises the engine start-up and
stop.
N.B.
- THE CODE CAN BE CLEARED IN ABOUT 30 SECONDS.
IN SOME CASES, HOWEVER, MORE TIME COULD BE RE-
QUIRED. BESIDES, THE CODE CAN BE CLEARED BY DIS-
CONNECTING THE CIRCUIT, AS WELL AS THE BATTERY
POWER SUPPLY AND FUSE CONNECTION. IF THE BAT-
TERY TERMINAL MUST BE DISCONNECTED, TAKE NOTE
OF THE RADIO CHANNELS. AFTER FINISHING THE OP-
ERATION, SET THE RADIO CHANNELS AGAIN.
- IN CASES IN WHICH THE SAME MALFUNCTION IS NOT
DETECTED ANYMORE DURING THE COURSE OF THE 40
ENGINE WARMING UP CYCLES, THE FAILURE CODE AND
FROZEN IMAGE DATA ARE CLEARED AUTOMATICALLY
FROM THE CONTROL UNIT MEMORY (ONLY IN VEHICLES
WITH EU SPECIFICATIONS).
Controlli di base del motore
Diagram of basic operations to check the engine
If the electronic control unit does not detect any diagnostic failure code during the malfunction phe-
nomenon test, and during the visual inspection no failure is detected, perform a progressive trouble-
shooting of circuits which are presumably the cause of malfunctions. In many cases, the areas causing
malfunctions can be quickly and efficiently identified by carrying out a basic check of the engine, as
indicated in the following diagram. Therefore, it is very important to carry out these checks to identify
engine failures.
1. Check that battery voltage is equal to 11 V or more, with the engine stopped
Charge or replace the battery, if necessary.
2. Check that the engine runs with the starter motor
3. Check if the engine does not start
Proceed with step 6, otherwise proceed with step 4.
IS - 426
4. Ignition timing check.
In case of M/T vehicles, set the gear in
neutral position.
Set the electric charge switches to
OFF.
Warm up the engine until the engine
coolant temperature reaches 90C or a
higher value.
If the diagnostic tester DS-21 is not
used, connect the T terminal of the
special tool connector to the ground
terminal, with a linking wire. If the di-
agnostic tester DS-21 is used, select
the option "T terminal ON" of the ac-
tuator control so as to short-circuit the
T terminal.
If it does not correspond
Connect the stroboscopic gun to the
ignition coil wire #4 (cylinder 4) to acti-
vate the signal light necessary to de-
tect correct engine timing.
Check that the flywheel reference mark
is within the parameters of the gauge
with a square hole to check ignition
timing located on the rear bottom plate.
Adjust the ignition timing by turning the cam angle
sensor.
Specific tooling
Characteristic
Specifications:
3 2 BTDC (Before Top Dead Centre)
IS - 427
5. Engine idle speed check
1. Connect the tester DS-21 to the Data Link Con-
nector interposing the special tool, or connect the
OBD II general scanning device directly to the Da-
ta Link Connector. Then check idle speed.
2. If the tester DS-21 or OBD II general scanning
device is not used, connect a speedometer to the
REV terminal.
Does the value measured match the specified val-
ues?
Adjust engine idle speed turning the idle adjust-
ment screw located on the throttle body otherwise
continue with troubleshooting according to the
malfunction phenomena.
AFTER CHECKING, AVOID THE SHORT CIRCUIT OF THE
T TERMINAL BY MEANS OF THE " ACTUATOR CONTROL"
FUNCTION.
Specific tooling
Characteristic
Specifications
850 - 950 rpm.
6. Fuel pressure check (simple control)
Check that there is enough fuel in the tank.
If the diagnostic tester DS-21 is not used:
- Remove the fuel pump relay and connect a linking wire, as shown in the figure.
Specific tooling
IS - 428
- Fasten the fuel pipe to the main pipe manually.
With the ignition switch set to ON, a fuel pressure
increase must be detected. Otherwise, check the
fuel pump for correct operation.
If the diagnostic tester DS-21 is used:
- connect the diagnostic tester DS-21 to the Data Link Connector interposing the special tool.
Specific tooling
- Fasten the fuel pipe to the main pipe manually,
and set the ignition switch to ON. Afterwards, se-
lect the option "Fuel pump control" between the
single functions so as to activate the fuel pump. A
fuel pressure increase must be detected. Other-
wise, check the fuel pump for correct operation.
IS - 429
7. Spark check
Remove the fuel pump relay from the
relay block.
Remove the ignition coils and the spark
plugs (all cylinders 1, 2, 3 and 4).
Fit the spark plug on the ignition coil.
Connect the ignition coil connector to
the coil.
Earth the spark plug.
Run the engine with the starter motor.
Check if the spark plugs produce
sparks. Replace, if necessary.
8. Fuel injector operation confirmation
Fit the spark plugs, ignition coils and
fuel pump relay. Connect the ignition
coil connector.
With a sound alarm, check the opera-
tion sound of the single injectors while
the engine is run with the starter motor
or at idle speed.
The sound of operation of all the injectors must be
heard. Otherwise, check the Fuel Injector Circuit.
9. Fuel pressure check
Warm up the engine.
With the ignition switch set to OFF, re-
move all the ignition coils and the spark
plugs.
Temporarily remove the main relay
and the fuel pump relay.
Fit a compression test gauge in the spark plug hole.
Push the accelerator pedal completely.
While the engine is run with the starter motor, measure the compression pressure.
IS - 430
Repeat the three previous steps to carry out the measurement on all the cylinders.
BE CAREFUL TO USE A BATTERY COMPLETELY CHARGED. BESIDES, CARRY OUT THE
MEASUREMENT AS SOON AS POSSIBLE.
Characteristic
Limit value:
1030 kPa
(10.5 kgf-cm)
Specified value:
1373 kPa
(14.0 kgf-cm)
Perform troubleshooting according to malfunction
phenomena.
Scanning device data (electronic control unit data)
The values indicated below are those obtained under "standard conditions" using the scanning device.
Please refer to these values.
However, there are cases in which the system works regularly even if the value measured differs from
the indicated values. Therefore, do not to pass judgement on the possible malfunction according to
these data under "standard conditions".
The value of data checking can vary significantly according to a slight difference in meas-
urement, measurement environment and deterioration due to the passing of time, and so
on. It is therefore difficult to indicate the reference values defined. Consequently, there are
cases in which malfunctions are detected also when the value measured is within the ref-
erence values.
As regards less important phenomena, as intermittent failures or irregular idle speed, per-
form a total assessment based on all the data checking options, sampling the data of
vehicles of the same type obtained under the same conditions, and comparing them.
In the case of the OBD II general scanning device, it is possible to read the data and mark
an asterisk in the following table.
When the data are checked with the engine running, the gearshift lever must be in a neutral
position, switch A/C must be set to OFF, and all the accessory switches must be set to OFF.
IS - 431
Diagnostic tester display Signal
abbrevia
tion
Vehicle conditions Reference values under
standard conditions
FUEL SUPPLY SYSTEM (Fuel
supply system status)
FSYS Minimum speed after warming up 02 (closed cycle)
CALCULATED LOAD (calculated
load value)
LOAD Minimum speed without load after warming
up
4.0-5.0%
2500 rpm without load after warming up 8.0-9.0%
COOLANT TEMPERATURE (en-
gine coolant temperature)
ECT Cold start ~Warming up running order The value must increase gradu-
ally
Engine completely warmed up 80-100C
During the failure-free function (at start-up) 20C
During the failure-free function (after start-up) 80C
SHORT CF (short term fuel com-
pensation)
SHRT Minimum speed after warming up -20-+20%
LONG CF (long term fuel com-
pensation)
LONG Minimum speed after warming up -20-+20%
ENGINE SPEED rpm With engine running at a constant speed There must not be substantial dif-
ferences, rpm
Minimum speed without load after warming
up
850-950 rpm
VEHICLE SPEED VS During running (measured with a speedome-
ter)
There must not be a significant
difference, Km/h
IGNITION ADVANCE (ignition
timing advance for cylinder No.1)
ITA At idle without load after warming up. With
idle switch set to OFF
5-9 Variations to be carried out
according to running conditions
INTAKE AIR TEMPERATURE IAT With the engine running Variations to be carried out ac-
cording to running conditions C
MANIFOLD ABSOLUTE PRES-
SURE (Inlet manifold absolute
pressure)
MAP With the ignition switch set to ON (suction
pipe released into the atmosphere) While
running at idle speed (after warming up, with-
out load)
Approx.100 kPa 28-35 kPa
MANIFOLD ABSOLUTE PRES-
SURE (Inlet manifold absolute
pressure)
MAP Standard conditions with the engine at idle 24 - 28 kPa
THROTTLE POSITION (throttle
absolute position)
TP With the accelerator pedal pushed Variations must be carried out ac-
cording to the pedal operation,%
IS - 432
Diagnostic tester display Signal
abbrevia
tion
Vehicle conditions Reference values under
standard conditions
OXYGEN SENSOR S1 (heated
oxygen sensor 1)
02,FP Minimum speed after warming up -5-5%
02,FV 0.05-0.95 V
OXYGEN SENSOR S2 (heated
oxygen sensor 2)
02,RP With the engine running at 2000 rpm, for 3
minutes or more, after warming up
12.5-87.5%
02,RV 0.05-0.95 V
Distance travelled once the MIL
was activated
DWM Without diagnostic failure code 0 Km
Diagnostic tester display Signal code Vehicle conditions Reference values under
standard conditions
BATTERY VOLTAGE BAT With engine running at 5000 rpm (25C),
bnb,
Approx. 14 V
ELECTRIC CHARGE DSW With the light switch, heating fan, anti-fog
system or radiator fan set to ON
"OFF" ->"ON"
AIR CONDITIONING (if
present)
AC With the air conditioner switch set to
"ECON" or "A/C"
"OFF" ->"ON"
THROTTLE POSITION
SWITCH CLOSED (throttle
position switch closed)
IDL When the throttle valve is changed from
fully closed to open status.
"OFF" ->"ON"
INJ ECTION PULSE AMPLI-
TUDE (fuel injection pulse am-
plitude)
TAU Cold start ~warming up running order The value
must decrease gradually
While the engine is running at idle speed
(after warming up, without load)
0.8-2.0 ms
Service of the electronic control unit and rele-
vant circuits
The electronic control unit and relevant circuits can
be serviced by measuring voltage and resistance
of the electronic control unit connector. In order to
identify the cause, measure voltage and resist-
ance of the electronic control unit external path.
Measure voltage and resistance during the system
inspection, according to the procedure described
below.
CAUTION
- THE ELECTRONIC CONTROL UNIT CAN NOT BE SERV-
ICED WITHOUT HELP. NEVER CONNECT A VOLTMETER
IS - 433
OR AN OHMMETER TO THE ELECTRONIC CONTROL UNIT
WHEN THE CONNECTOR IS NOT CONNECTED TO IT.
- WHILE TESTING CONTINUITY OR MEASURING RESIST-
ANCE, TURN OFF THE IGNITION SWITCH. AFTERWARDS,
DISCONNECT THE ELECTRONIC CONTROL UNIT CON-
NECTOR.
KEY:
2. Cable harness
3. Connector
1. Fitting the special tool. First of all, fit the special
tool between the electronic control unit and the ve-
hicle cable harness.
2. Measure voltage between the respective con-
nector terminals of the special tool.
3. Check that the values detected comply with
specifications indicated in the following " STAND-
ARD VOLTAGE" table.
System to be checked Terminals Measurement conditions Reference values
Power supply system 7 (+B1) - 23 (E1) With ignition switch set to "ON" Battery voltage
36 (+B2) - 23 (E1) With ignition switch set to "ON"
1 (BAT) -23 (E1) At any moment
Pressure sensor 46 (VCPM) - 47
(E2PM)
With ignition switch set to "ON" 4.5 - 5.5 V
15(PIM)-47(E2PM) Sensor at ambient pressure 2.2 - 3.1 V
After the engine start-up: The value changes
according the accel-
erator opening angle
Throttle valve sensor 16 (VC )- 17 (E2) With ignition switch set to "ON" 4.5 - 5.5 V
44 (VHT) - 17 (E2) Throttle valve completely closed 0.4 - 0.8 V
Throttle valve completely open 3.2 - 5.0 V
Engine coolant temperature
sensor
45 (THW) - 17 (E2) While warming up the engine (water
temperature: 60-120)
0.2 - 1.0 V
Intake air temperature sen-
sor
76 (THA) -17 (E2) While warming up the engine 0.1 - 4.8 V
Vehicle speed sensor 37 (SPD)-23 (E1) The driving wheels are slowly turned 0 - 5 V
Cam angle sensor 22 (N2+) - 52 (N2-) While the engine is running at idle
speed
Wave shape produc-
tion
Front O2 sensor 75 (OX1)- 17 (E2) After keeping the vehicle speed at
3000 rpm for four minutes
0.05-0.95 V
IS - 434
Rear O2 sensor 73 (0X3)-17 (E2) After keeping the vehicle speed at
3000 rpm for four minutes
0.05-0.95 V
Ignition system (ionic current
sensor)
14 (ICMB)- 43 (IE) While the engine is running at idle
speed
Wave shape produc-
tion
Injectors 27 (#10) - 23 (E1) With ignition switch set to "ON" Battery voltage
26 (#20) - 23 (E1)
25 (#30) - 23 (E1) During the starter motor activation Impulse production
24 (#40) - 23 (E1)
Ignition 60 (IG1) - 23 (E1) With ignition switch set to "ON" Battery voltage
59 (IG2) - 23 (E1)
58 (IG3) - 23 (E1) During the starter motor activation Impulse production
57 (IG4) - 23 (E1)
Vacuum switching valve -
idle speed increase
56 (VSV2) - 82 (E01) With ignition switch set to "ON" Battery voltage
With the headlight switch of the anti-
fog system, the heating fan, radiator
fan thermoswitch and the stop light
switch set to "ON" while the engine
is running at idle speed and after it
has been warmed up.
0 - 0.5 V
Fuel pump 30 (FC2) - 23 (E1) With the fuel pump off Battery voltage
While the engine is running at idle
speed (or it is activated with the
starter motor)
2 V or less
VF monitor 34 (VF) - 23 (E1) After keeping the vehicle speed at
3000 rpm for four minutes (terminal
T short-circuited)
0 - 5 V (Impulse)
Headlight 6 (TRRQ) - 23 (E1) With the headlight switch set to "ON" 0-0.5 V
With the headlight switch set to
"OFF"
Battery voltage
Anti-fog system 10 (DEF) - 23 (E1) With the anti-fog system switch set
to "ON"
Battery voltage
With the anti-fog system switch set
to "OFF"
0 - 0.5 V
Fan 39 (BLW) - 23 (E1) With the heater fan switch set to
"ON"
0 - 0.5 V
IS - 435
With the heater fan switch set to
"OFF"
Battery voltage
Radiator fan control system 11 (A/T) - 23 (E1) With the water temperature switch
set to "ON"
1 V or less
With the water temperature switch
set to "OFF"
Battery voltage
Stop light 40 (STP) - 23 (E1) With the stop light switch to set "ON" Battery voltage
With the stop light switch set to
"OFF"
0 - 0.5 V
Vapour bleeding control sys-
tem
79 (PRG) - 23 (E1) Running at idle speed Battery voltage
Speed (3000 rpm) Impulse production
engine revs output 3 (REV) - 23 (E1) While the engine is running at idle
speed
Impulse production
Communication signal con-
trol system
8 (SIO1)-23 (E1) While the engine is running at idle
speed
Impulse production
EGR system 80 (VSV1) - 23 (E01) While the engine is running at idle
speed
Battery voltage
3000 rpm speed after warming up
the engine
0 - 0.5 V
P105 - Malfunzionamento circuito pressionebarometrica/pressione
assoluta del collettore
WIRING DIAGRAM (MAP) - INLET MANIFOLD ABSOLUTE PRESSURE CIRCUIT (EURO3)
1. ECU EFI control unit 2. Manifold absolute pressure sensor (MAP) 3. Cable harness side view con-
nector
IS - 436
WIRING DIAGRAM (MAP) - INLET MANIFOLD ABSOLUTE PRESSURE CIRCUIT (EURO3)4
1. ECU EFI control unit 2.DRACO control unit 3. MAP sensor, inlet manifold absolute pressure. 4. Cable
harness side connector
IS - 437
CIRCUIT DESCRIPTION
The manifold absolute pressure sensor measures
the inlet manifold pressure as voltage. Since the
manifold absolute pressure sensor does not take
atmospheric pressure as a measurement method,
but measures the absolute pressure inside the in-
let manifold (vacuum corresponds to 0 pressure),
it is not influenced by atmospheric pressure fluc-
tuations caused by altitude and other factors. This
allows the sensor to check the air-fuel ratio at the
suitable level under all conditions.
M.A.P.: Absolute pressure in the air inlet manifold
N.B.
AFTER CONFIRMING THE DIAGNOSTIC FAILURE CODE P0105, USE THE OBD II GENERAL
SCANNING DEVICE OR DIAGNOSTIC TESTER TO CONFIRM THE MANIFOLD ABSOLUTE PRES-
SURE IN " CURRENT DATA" .
DIAGNOSTIC FAILURE CODE DETECTION CONDITIONS - P0105
P0105 - Open circuit or short circuit in the manifold absolute
pressure sensor circuit
- interrupted or short-circuited wire in the manifold absolute
pressure sensor cable harness
- manifold absolute pressure sensor
- engine electronic control unit
If the electronic control unit detects the diagnostic failure code P0105, the failure-free function which
keeps the ignition timing and the injection volume constant is activated, allowing vehicle riding.
ABSOLUTE PRESSURE IN THE INLET MANIFOLD
0 kPa PIM circuit in short circuit
130 kPa - VCPM circuit open or short-circuited - PIM circuit open - E2PM
circuit open
For the Model EURO 4, the circuits described in the table above comprise the cable harnesses before
and after the ECU DRACO control unit and on the DRACO.
CHECKING PROCEDURE - USING THE DIAG-
NOSTIC TESTER OR OBD II GENERAL SCAN-
NING DEVICE.
1. Checking MAP sensor output value
With the ignition switch set to OFF,
connect the diagnostic tester directly to
the (DTC) Data Link Connector with
the special tool.
Specific tooling
IS - 438
After setting the ignition switch to ON, turn on the tester main switch. Read the inlet manifold
absolute pressure value of the diagnostic tester. If the value measured matches the atmos-
pheric pressure value (about 100 kPa) check the malfunction that is detected intermittently
or the inefficient contacts (see relevant section), otherwise proceed with step 2.
2. Checking MAP sensor power supply voltage
After setting the ignition switch to OFF also turn off the Diagnostic tester main switch.
Connect the special tool to the ECU EFI.
(For the Model EURO 4: connect the special tool between the ECU EFI control unit and the cable
harness connectors coming from the ECU DRACO control unit).
Specific tooling
020463Y ECU-EFI interface cable harness to check the injection system electrical values.
Check that voltage between terminals
46 and 47 matches the value specified
with the ignition switch set to ON.
Characteristic
Voltage specified Value:
4.5 - 5.5 V
If no voltage is detected, check the power supply
circuit of the electronic control unit, then check or
replace the electronic control unit.
3. MAP sensor check
move the MAP sensor from the throttle
body with the cable harness towards
the electronic control unit.
IS - 439
Set the ignition switch and then the
tester main switch to ON.
Apply a negative pressure to the MAP
sensor, with the MityVac device.
Check the manifold absolute pressure
value according to the following speci-
fications.
Vacuum applied Value displayed on the scanning device
0 kPa About 100 kPa (760 mm Hg)
27 kPa (200 mm Hg) About 73 kPa (560 mm Hg)
67 kPa (500 mm Hg) About 33 kPa (260 mm Hg)
If values measured match those indicated in the
table, check for possible intermittent malfunctions
caused by problems in the vacuum duct, cable
harness or connector, otherwise proceed with step
4.
4. Checking the cable harness between the
MAP sensor and the electronic control unit
Model EURO 3
Set the tester main switch and the ig-
nition switch to OFF.
Disconnect the cable harness from the
MAP sensor. Fit the MAP sensor on the
throttle body.
Disconnect the special tool connectors
on the electronic control unit side.
Connector X44 on the sensor side - connector 47
on the E2PM electronic control unit side.
Connector X45 on the sensor side - connector 15
on the PIM electronic control unit side.
Connector 46 on the sensor side - connector 46 on
the VCPM electronic control unit side.
IS - 440
Repair or replace the cable harness or connector,
if necessary, otherwise replace the MAP sensor.
N.B.
APPLY FUEL ONTO THE MAP SENSOR O-RING, THEN IN-
SERT IT BEING EXTREMELY CAREFUL.
CHECKING PROCEDURE - WITHOUT USING THE DIAGNOSTIC TESTER OR OBD II GENERAL
SCANNING DEVICE
1. Checking the PIM input signal of the electronic control unit
Connect the special tool (For the Model EURO 4, connect the special tool between the EFI
ECU control unit and the cable harness connectors coming from the DRACO control unit).
Specific tooling
With the ignition switch set to ON,
measure voltage between terminals 15
and 47 (PIM-E2PM).
Characteristic
specified value
3.3 - 4.0V
If the value measured does not match the specified
value, proceed with step 2.
2. Checking the sensor power supply voltage
Check that voltage between terminals
46 and 47 matches the specified value.
Characteristic
4.5 - 5.5 V
If no voltage is detected, check the power supply
circuit of the electronic control unit, then check or
replace the electronic control unit (for model EU-
RO 4, check cable harnesses and also that the EFI
ECU control unit is downstream as well as up-
stream the DRACO control unit) otherwise pro-
ceed with step 3.
3. MAP sensor check
IS - 441
Remove the MAP sensor from the
throttle body with the cable harness
connected to the control unit.
Apply a negative pressure to the MAP
sensor, with the MityVac device.
Check that voltage between terminals 15 and 47 matches the voltage specified according
to the following conditions:
Vacuum applied Value displayed on the voltmeter
0 kPa 3.3 - 4.0 V
27 kPa (200 mm Hg) 2.6 - 3.1 V
67 kPa (500 mm Hg) 1.1 - 1.4 V
If the value measured matches the values indica-
ted in the table, check for possible intermittent
malfunctions caused by problems in the vacuum
duct, cable harness or connector, otherwise pro-
ceed with step 4.
4.Checking the cable harness between the
MAP sensor and the electronic control unit.
Model EURO 3
Set the ignition switch to OFF.
MAP sensor. Fit the MAP sensor on the
throttle body.
Connector X44 on the sensor side -
connector on the E2PM electronic con-
trol unit side.
Connector X45 on the sensor side - connector on
the PIM electronic control unit side.
IS - 442
Connector X46 on the sensor side - connector on
the VCPM electronic control unit side.
Repair or replace the cable harness or connector,
if necessary, otherwise replace the MAP sensor.
Model EURO 4
Check cable harnesses downstream and up-
stream the ECU DRACO and on the ECU DRACO
itself in the following order
Test the cable harness in the vehicle
connecting the special tool to the DRA-
CO connectors on the device side.
Test the cable harness in the EFI ECU
control unit connecting the special tool
to the DRACO connectors on the con-
trol unit side.
If there are no short circuits or open circuits on both
cable harnesses, the malfunction could be caused
by the sensor or the DRACO.
To check for correct operation of the DRACO pro-
ceed as follows:
a) Disconnect the cable harness of the DRACO to
the EFI ECU control unit
b) Connect the special tool between the EFI ECU
connectors and cable harness connectors to the
vehicle devices so as to bypass the DRACO.
c) carry out the check as in Step 3. If failures are
detected, the problem is in the DRACO control unit
which must be replaced, otherwise replace the
sensor.
APPLY FUEL ONTO THE MAP SENSOR O-RING, THEN IN-
SERT IT BEING EXTREMELY CAREFUL.
IS - 443
P0110 - Malfunzionamento circuito temperatura aria immessa
KEY:1. ECU electronic control unit 2. Cable harness side connector 3. Intake air temperature sensor
(IAT) 4. Ground node
Model EURO 4
KEY:1. ECU electronic control unit 2. Cable harness side connector 3. Intake air temperature sensor
(IAT) 4. Ground node 5. DRACO control unit
IS - 444
IAT SENSOR CIRCUIT DESCRIPTION
The intake air temperature sensor IAT sensor,
measures the air temperature in the intake pipe
between the air filter and the throttle body. The
thermistor inside the sensor changes the resist-
ance value according to the intake air temperature.
The lower the temperature value is, the higher the
thermistor resistance value is and, the higher the
intake air temperature is, the lower the thermistor
resistance value is.
When the IAT sensor resistance value varies ac-
cording to temperature variations, also the THA
terminal potential changes. According to this sig-
nal, the engine electronic control unit (ECU) in-
creases the fuel volume injected improving riding
conditions while operating with the engine cold.
For the Model EURO 4, the circuits in question
comprise the cable harnesses downstream and
upstream the DRACO control unit and on the DRA-
CO itself.
Failure code Diagnostic failure code detection
Conditions
Affected area
P0110 Short circuit or open circuit in the IAT sensor
circuit.
- interrupted or short-circuited cable in the IAT
sensor cable harness
- IAT sensor, intake air temperature
- ECU
Once the diagnostic failure code P0110 is confirmed, use the diagnostic tester to measure the intake
air temperature by:"CURRENT DATA".
Temperature displayed Malfunction
-30 Open circuit
about 130 Short circuit
Checking procedure
If the diagnostic failure codes P0110 (IAT - Intake air temperature sensor circuit), P0115
(ECT - Engine coolant temperature sensor circuit), and P0120 (TPS - Throttle position sen-
sor) are generated at the same time, the Sensor ground E2 could be open.
Read the frozen image data using the diagnostic tester. As frozen image data record the
engine conditions at the moment the defect is detected, these data are useful to determine
IS - 445
during the troubleshooting phase, if at the moment of failure checking, the vehicle was
working or at standstill, if the engine was hot or not, if the air/fuel ratio was lean or rich etc.
USING THE DIAGNOSTIC TESTER DS-21 OR
DIGITEK OR OBD II GENERAL SCANNING DE-
VICE
Step 1
1. With the ignition switch set to OFF, connect the
Diagnostic tester to the OBD connector, vehicle,
data link, with the special tool.
to ON. Read the intake air temperature value on
the diagnostic tester.
DOES THE VALUE MEASURED MATCH THE
ONE SPECIFIED?(for example, intake air temper-
ature with cold engine about 20C); If SO: Check
the malfunction detected intermittently or ineffi-
cient contacts, (see relevant section);
If NOT Value measured: about - 30C, proceed
with Step 2, Value measured: about - 130C, pro-
ceed with Step 4.
Specific tooling
Step 2
Checking interrupted cables in the cable harness
or inside the engine electronic control unit ECU (1).
1. Set the tester switch and the ignition switch to
OFF. 2. Disconnect the intake air temperature sen-
sor connector (IAT). 3. Close the contact (through
a conductive wire) between terminals (X33) and
(X34) of the IAT sensor. 4. Set the ignition switch
and the tester switch to ON. Is the value measured
about 130C?
If SO: Connect the IAT sensor connector connec-
tion if it is the one specified, then replace the IAT
sensor.
If NOT: see Step 3.
IS - 446
Specific tooling
Step 3
Checking for interrupted cables in the cable harness or inside the ECU
1. Set the tester switch and the ignition switch to OFF.
2. Connect the special tool for interface sub-wiring harness and refer to the relevant section for use.
Specific tooling
3. Disconnect the linking cable from the IAT sensor
connector.
4. Afterwards, connect it between terminals (76)
and (17) of the special tool connector.
5. Set the ignition switch and the tester switch to
ON. Read the air temperature value measured by
the diagnostic tester.
Is the value measured about 130C?:
If SO (EURO 3): the IAT sensor connection cable
harness is interrupted. Repair or replace the cable
harness.
If NOT (EURO 3): interruption inside ECU. Check
or replace the engine electronic control unit. (see
the relevant section).
If SO (EURO 4) - transfer the 4 interface Sub-wir-
ing harness connectors, from the ECU to the DRA-
CO; - reconnect the DRACO to the ECU through
the original connectors. - jumper PIN 76 and 17
and check the air temperature value Is the tem-
perature value approx. 130C?
If SO (EURO 4): the IAT sensor connection cable
harness is interrupted. Repair or replace the cable
harness.
If NOT (EURO 4): the DRACO or the cable har-
ness connecting with the ECU is interrupted. Fix
the cable harness or replace the DRACO.
IS - 447
Step 4
Checking short circuits in the cable harness or in-
side the engine electronic control unit ECU or
DRACO (1).
1. Set the tester main switch and the ignition switch
to OFF.
2. Disconnect the intake air temperature sensor
connector (IAT).
to ON. Read the intake air temperature value on
the diagnostic tester; Is the value measured about
- 30C?
If SO: replace the IAT sensor,
If NOT (EURO 3): proceed with Step 5.
If NOT (EURO 4): Check for short circuits in the
IAT sensor cable harness; 1. Set the ignition
switch and the tester switch to OFF. 2. Disconnect
connector "B" from the DRACO 3. Switch to ON
and read the intake air temperature
Is the value measured about - 30C?
If SO (EURO 4): Repair and replace the IAT sen-
sor connection cable harness.
If NOT (EURO 4): Check for short circuits in the
DRACO or in the connection cable harness to the
ECU; 1. Set the ignition switch and the tester
switch to OFF. 2. Disconnect connector "B" from
the ECU 3. Switch to ON and read the intake air
temperature
Is the value measured about - 30C?
If SO (EURO 4): There is a short circuit in the
DRACO or in the connection cable harness to the
ECU. Repair and replace the connection cable
harness or the DRACO.
If NOT (EURO 4): There is a short circuit inside the
ECU. Check and replace the ECU. (see the rele-
vant section EF-36)
Step 5
IS - 448
Checking for short circuits in the cable harness or
inside the ECU (2).
1. Set the tester switch and the ignition switch to
OFF. 2. Disconnect connector "B" of the special
tool from the ECU. 3. Set the ignition switch and
the tester switch to ON. Read the intake air tem-
perature value on the diagnostic tester.
Is the value measured about -30C?
If SO: repair and replace the cable harness or the
connector.
If NOT: check and replace the ECU. (see the rel-
evant section EF-36)
NOTE: This diagnosis procedure generates fur-
ther temporary diagnostic failure codes, for exam-
ple P0105, and P0115, which can be cleared from
the memory at the end of the diagnosis.
KEY:1. EFI ECU control unit 2. Connector B 3. Cable harness side 4. Special tool (SST)
DIAGNOSIS WITH MULTIMETER AND INTERFACE WIRING.
Step 1
Checking the THA signal entering the ECU.
1. Connect the interface wiring. (See the relevant section "Connection of the special tool, Interface
wiring").
2. With the ignition switch set to ON, measure voltage between connectors (76) and (17) (THA-E2)
according to the following conditions:
Intake air temperature Specified value
20 C 1.8 - 2.9 V
60 C 0.6 - 1.2 V
IS - 449
DOES THE VALUE MEASURED MATCH THAT
ONE SPECIFIED?
If SO (EURO3): Check the malfunction that is de-
tected intermittently or inefficient contacts
If SO (EURO4): Check the signal entering the
DRACO 1. connect the interface wiring between
the DRACO and the vehicle cable harness and re-
store the original connection between the DRACO
and the ECU. 2. Repeat voltage checks as in Step
1.
IS THE VOLTAGE MEASURED 5.0 V ?
There is an interruption in the DRACO or in the
connection cable harness to the ECU. check con-
tinuity between: 11/22 76R<1 Ohm =no failure
detected 21/22 17R<1 Ohm =replace DRACO or
cable harness.
DOES THE VALUE MEASURED MATCH THE
ONE SPECIFIED? If SO (EURO4): Check the
malfunction that is detected intermittently or insuf-
ficient contacts
If NOT (EURO4): 1. Connect the interface wiring
020463Y between the ECU and the DRACO and
restore connections between the DRACO and the
vehicle cable harness. 2. Repeat voltage checks
as in Step 1.
If NOT : proceed with Step 2.
Step 2
Checking the cable harness between the IAT sen-
sor and the ECU electronic control unit.
2. Disconnect the cable harness from the IAT sen-
sor.
3. Disconnect the special tool connectors (inter-
face wiring), ECU side, electronic control unit.
4. Referring to the section "Checking cables and
connectors" and to the "IAT sensor circuit dia-
gram" at the beginning of the chapter, check there
are no interrupted or short-circuited cables in the
IS - 450
cable harness and connector, between the follow-
ing terminals: IAT sensor terminal (X33) - ECU
terminal 76 (THA), IAT sensor terminal (X34) -
ECU terminal 17 (E2),
If the values measured do not match specifications
in the table, replace the cable harness or the con-
nector.
CONTINUITY CHECK
Affected terminals Value measured
76 - X33 <1 (Ohm)
17 - X34 <1 (Ohm)
Step 3
IAT sensor check
Check and replace the IAT sensor, if necessary, otherwise check or replace the engine electronic control
unit.
P0115 - Malfunzionamento circuito temperatura liquido raffreddamento
motore
Using the tester DS-21 or OBD II general scanning device
1)
1. With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link Connector
through the special tool, or connect the OBD II general scanning device directly to the Data Link Con-
nector.
Specific tooling
to ON. Read the coolant temperature on the diag-
nostic tester DS-21 or on the OBD II general scan-
ning device.
IS - 451
If the value measured matches the actual water
temperature, check the malfunction that is detec-
ted intermittently or inefficient contacts (see the
relevant section); otherwise, if it is -40C, proceed
with step 2; if it is 140C or higher, proceed with
step 4.
2) Checking interrupted cables in the cable
harness or inside the engine electronic control
unit ECU
1. Set the tester main switch and then the ignition
switch to OFF.
2. Disconnect the engine coolant temperature sen-
sor connector (ECT).
3. Connect a linking wire between terminals (X30)
and (X31) of the ECT sensor.
Specific tooling
4. Set the ignition switch and then the tester main switch to ON. Read the engine coolant temperature
value on the diagnostic tester DS-21 or on the OBD II general scanning device. If the value measured
is equal to 140C or higher, check the connector connection or the ECT sensor terminal. If it is satis-
factory, replace the ECT sensor, otherwise proceed with step 3.
3)
Checking interrupted cables in the cable harness or inside the engine electronic control unit (2)
1. Set the tester main switch and then the ignition switch to OFF.
2. Set the special tool (sub-wiring harness).
Specific tooling
3. Disconnect the linking wire from the ECT sensor
connector.
4. Afterwards, connect the linking wire between
terminals (46) and (7) of the special tool connector.
IS - 452
to ON. Read the engine coolant temperature value
on the diagnostic tester DS-21 or on the OBD II
general scanning device.
Is the value measured equal to 140 C or higher?:
If SO: the wire between the ECT sensor and the
electronic control unit is interrupted. Repair or re-
place the cable harness.
If NOT (EURO 3): check the connector connection
and the electronic control unit terminals. If this is
in order, replace the engine electronic control unit
(see the relevant section).
If NOT (EURO 4): the DRACO or the cable har-
ness connecting with the ECU is interrupted. Fix
the cable harness or replace the DRACO.
Check cable harnesses downstream and up-
stream the DRACO and on the DRACO itself in the
following order
Test the cable harness in the EFI ECU
control unit connecting the special tool
to the DRACO connectors on the con-
trol unit side.
Check the DRACO works properly: dis-
connect the DRACO cable harness on
the device side of the vehicle, connect
the special tool to the relevant connec-
tors and follow the procedure of Step 3
from the start. If no failures are detec-
ted, the problem is in the DRACO con-
trol unit which must be replaced.
Test the cable harness in the vehicle
connecting the special tool to the DRA-
CO connectors on the device side.
If all the tests do not work, go back to Step 2.
4)
MODEL EURO 4
IS - 453
side the electronic control unit EFI ECU or DRA-
CO.
switch to OFF.
2. Disconnect the engine coolant temperature sen-
sor connector (ECT).
to ON. Read the coolant temperature value on the
diagnostic tester DS-21 or on the OBD II general
scanning device.
If the value measured is equal to -40C replace the
ECT sensor, otherwise proceed with step 5.
5)
side the electronic control unit ECU or DRACO
(Model EURO 4)
switch to OFF.
2. Disconnect connector B of the special tool from
the electronic control unit connector.
KEY:
2. Connector B
3. Cable harness side connector
4. Diagnostic socket
3. Set the ignition switch and the tester main switch to ON. Read the engine coolant temperature value
on the diagnostic tester DS-21 or on the OBD II general scanning device.
Is the value measured equal to -40C?
If SO (EURO 3): repair or replace the cable harness or the connector otherwise check or replace the
engine electronic control unit (see the relevant section).
If NOT (EURO 4): the DRACO or the connection cable harness with the ECU is interrupted. Fix the
cable harness or replace the DRACO. Check cable harnesses downstream and upstream the DRACO
and on the DRACO itself as specified in Step 3.
IS - 454
Without using the diagnostic tester DS-21 or
OBD II general scanning device
1) Checking the input signal of the THW elec-
tronic control unit
1. Connect the special tool (For the Model EURO
4, connect the special tool between the EFI ECU
control unit and the cable harness connectors
coming from the DRACO control unit).
2. With the ignition switch set to ON, measure volt-
age between connectors (45) and (17) (THW-E2)
according to the following conditions:
Intake air temperature Specified value
20 C 1.8 - 2.9 V
60 C 0.6 - 1.2 V
If the value measured matches the specified value
check the malfunction that is detected intermittent-
ly or due to false contact (for the model EURO 4
check the cable harnesses and also that the EFI
ECU control unit is downstream as well as up-
stream the DRACO control unit, see the relevant
paragraph), otherwise proceed with step 2.
2) Checking the cable harness between the
ECT sensor and the electronic control unit
Model EURO 3
2. Disconnect the cable harness from the ECT
sensor.
3. Disconnect the special tool connectors on the
electronic control unit side.
4. check there are no interrupted or short-circuited
wires in the cable harness and connector.
(X30) connector on the sensor side - connector 45
on the electronic control unit side (THW).
(X31) connector on the sensor side - connector 17
on the electronic control unit side (E2).
Repair and replace the cable harness or the con-
nector, if necessary.
IS - 455
Model EURO 4
Proceed as for the model EURO 3, but checking
cable harnesses downstream as well as upstream
the DRACO control unit and on the DRACO itself.
With the special tool, check for continuity on the
following lines:
(X30) connector on the sensor side - connector
(B10) on the DRACO unit side
Connector (2/10) on the DRACO unit - connector
(45) on the electronic control unit side (THW).
(X31) connector on the sensor side - connector
(B4) on the DRACO unit side
Connector (3/21) on the DRACO unit - connector
(17) on the electronic control unit side (E2).
3)
Check and replace the ECT sensor, if necessary.
4)
Check and replace the engine electronic control unit.
KEY:
IS - 456
1. Cable harness side
3. To the instrument panel (indicate the engine temperature)
4. BNDR
Model EURO 4
KEY:
3.To the instrument panel (indicate the engine temperature)
4.BNDR
6. DRACO control unit
CIRCUIT DESCRIPTION
The thermistor inside the engine coolant temperature sensor modifies the resistance value according
to the engine coolant temperature. The sensor structure and connection to the electronic control unit is
like the one for the diagnostic failure code P0110 (intake air temperature circuit malfunction).
Failure code Diagnostic failure code detection Conditions Affected area
P0115 Interrupted or short-circuited wire in the engine
coolant temperature sensor circuit
- Interrupted or short-circuited wire in the engine
coolant temperature sensor circuit
For the Model EURO 4, the circuits described in the table above comprise the cable harnesses down-
stream and upstream the DRACO control unit and on the DRACO itself.
AFTER CONFIRMING THE DIAGNOSTIC FAILURE CODE P0115, USE THE OBD II GENERAL
SCANNING DEVICE OR DIAGNOSTIC TESTER DS-21 TO CONFIRM THE ENGINE COOLANT
TEMPERATURE IN THE CURRENT DATA.
Once the diagnostic failure code P0110 is confirmed, use the diagnostic tester to measure the intake
air temperature by:"CURRENT DATA".
IS - 457
Temperature displayed Malfunction
-30 Open circuit
about 130 Short circuit
Checking procedure
If the diagnostic failure codes P0110 (intake air temperature circuit malfunction), P0115 (engine coolant
temperature circuit malfunction), and P0120 (Throttle/pedal position sensor "A" switch malfunction) are
generated at the same time, the Sensor ground E2 could be open. Read the frozen image data using
the diagnostic tester DS-21 or OBD II general scanning device. As frozen image data record the engine
conditions at the moment the defect is detected, these data are useful to determine during the trouble-
shooting phase, if at the moment of failure checking, the vehicle was working or at standstill, if the engine
was hot or not, if the air/fuel ratio was lean or rich etc.
P0116 - Problemi funzionali portata circuito temperatura liquido
raffreddamento motore
KEY:
3. To the instrument panel (indicate the engine temperature)
4. BNDR
Circuit description Refer to Engine Coolant Temperature Circuit Malfunction.
IS - 458
Conditions
Affected area
P0116 When the engine is started, the coolant tem-
perature is -7.5C or higher, and lower than 40
C. After about 5 minutes the engine is running,
the coolant temperature sensor value is about
40C or lower, (measurement logic with two in-
terventions)
- Cooling system
If the diagnostic failure codes P0115 (engine coolant temperature circuit malfunction) and
P0116 (Functional problems/engine coolant temperature circuit capacity) are generated at
the same time, the engine coolant temperature sensor circuit could be open.
Read the frozen image data using the diagnostic tester DS-21 or OBD II general scanning
device. As frozen image data record the engine conditions at the moment the defect is de-
tected, these data are useful to determine during the troubleshooting phase, if at the moment
of failure checking, the vehicle was working or at standstill, if the engine was hot or not, if
the air/fuel ratio was lean or rich etc.
To perform troubleshooting in the water temperature sensor system, using only the diag-
nostic tester DS-21 or OBD II general scanning device allows to determine if failure causes
are interrupted, short-circuited wires P0115 or functional problems P0116.
1.
If other codes are generated apart from the diagnostic failure code P0116 go to the diagnostic failure
code operation diagram applicable, otherwise proceed with step 2.
2.
Check efficiency and replace the thermostat, if necessary, if it is efficient, replace the engine coolant
temperature sensor ECT.
IS - 459
Malfunzionamento circuito interruttore sensore posizione pedale farfalla
KEY:
A. comp. open
B. comp. closed
3. BNDR
Model EURO 4
KEY
A. comp. open
B. comp. closed
IS - 460
3. BNDR
5. DRACO control unit
Circuit description
The throttle valve sensor is fitted on the throttle
body and is used to measure the opening angle of
the throttle valve. With the throttle valve complete-
ly closed, a voltage equal to about 0.4-0.8 V is
applied to the VTH terminal of the engine elec-
tronic control unit. The voltage applied to VTH
terminals of the engine electronic control unit in-
creases proportionally to the throttle valve opening
angle, until reaching a value equal to about 3.5-5.0
V when the throttle valve is completely open. The
engine electronic control unit determines the ve-
hicle riding conditions according to the signals
input by the VTH terminal, it is considered as one
of the adopted parameters to correct air-fuel ratio,
power increase and to control fuel closure, etc.
For the Model EURO 4, the circuits in question
comprise the cable harnesses downstream and
upstream the DRACO control unit and on the DRA-
CO itself.
KEY:
2. Engine ECU
Conditions
Affected area
P0120 Condition (1) or (2) continues with more than
0.6 seconds:
1. VTH <0.2 V
2. VTH >4.8 V
- Interrupted or short-circuited wire in the throt-
tle valve sensor circuit
For the Model EURO 4, the circuits described in the table above comprise the cable harnesses down-
stream and upstream the DRACO control unit and on the DRACO itself.
After confirming the Diagnostic Failure Code P0120, use the diagnostic tester DS-21 or OBD II general
scanning device to confirm the throttle valve opening degree and the closed throttle position switch.
IS - 461
Throttle valve opening
position
affected area
Completely closed Completely open
0% 0% VC line open, interrupted or short-circuited wire in VTH line
About 100% about 100% E2 line open
Using the tester DS-21 or OBD II general scan-
ning device
1. Checking the throttle valve sensor output
value
connect the diagnostic tester DS-21 to
the Data Link Connector through the
special tool, or connect the OBD II gen-
eral scanning device directly to the Da-
ta Link Connector.
Specific tooling
Set the ignition switch and the tester main switch to ON. Read the throttle valve opening
value on the diagnostic tester DS-21 or on the OBD II general scanning device.
Throttle valve opening:
Completely closed: 0%
Completely open: 100%
If the opening value does not match, check the malfunction that is detected intermittently or due to false
contact (see the relevant section).
2. Checking the power supply voltage on the throttle valve sensor cable harness side
Set the tester main switch and then the ignition switch to OFF.
Disconnect the throttle valve sensor connector.
Measure voltage between the terminals (X99) of the cable harness connector and chassis
ground, with the ignition switch set to ON.
Characteristic
4.5 - 5.5 V
IS - 462
If the voltage matches the specified value proceed
with step 5, otherwise with step 3.
3. Throttle valve sensor check
Measure resistance between the respective connector terminals A.
Terminal Condition Standard value
X99 - XT1 - 2.5 - 6.0
XT1 - XT0 Throttle valve completely closed 0.1 - 1.3
XT1 - XT0 Throttle valve completely open 1.7 - 4.2
If no failures are detected during checks replace
the throttle valve sensor, otherwise proceed with
step 4.
4. Checking the input signal of the VTH elec-
tronic control unit
Connect the special tool (For the Model
EURO 4, connect the special tool be-
tween the EFI ECU control unit and the
cable harness connectors coming from
the DRACO control unit).
measure voltage between connectors
44 and 17 (VTH-E2) according to the
following conditions.
Throttle status Specified value
Completely closed 0.4 - 0.8 V
IS - 463
Completely open 3.5 - 5.0 V
If the value measured matches the specified value, check or replace the EFI ECU electronic control
unit, otherwise check the cable harness and the connector between the engine electronic control unit
and the throttle valve sensor (VTH line) for interrupted or short-circuited wires (in this case, for the model
EURO 4, possible failures are to be searched for in the cable harnesses downstream and upstream the
DRACO control unit or can derive from an incorrect operation of the DRACO).
5. Checking the power supply voltage on the throttle valve sensor electronic control unit side
With the ignition switch set to ON, measure voltage between connectors 16 and 17 (VTH-
E2).
Characteristic
4.5 - 5.5 V
value, check or replace the EFI ECU electronic
control unit, otherwise check the cable harness
and the connector between the engine electronic
control unit and the throttle valve sensor (VC line)
for interrupted or short-circuited wires (in this case,
for the model EURO 4, possible failures are to be
searched for in the cable harnesses downstream
and upstream the DRACO control unit or can de-
rive from an incorrect operation of the DRACO).
If no voltage is detected, check the electronic con-
trol unit power supply circuit.
Without using the diagnostic tester DS-21 or
OBD II general scanning device
1. Checking the input signal of the VTH elec-
tronic control unit
Connect the special tool (For the Model
EURO 4, connect the special tool be-
tween the EFI ECU control unit and the
IS - 464
cable harness connectors coming from
the DRACO control unit).
measure voltage between connectors
44 and 17 (VTH-E2) according to the
following conditions.
Completely closed 0.4 - 0.8 V
Completely open 3.5 - 5.0 V
value, check the malfunction that is detected in-
termittently or due to false contact (see the rele-
vant section).
2. Throttle valve sensor check
Disconnect the throttle valve sensor A.
Terminal Condition Standard value
X99 - XT1 - 2.5 - 6.0
XT1 - XT0 Throttle valve completely closed 0.1 - 1.3
XT1 - XT0 Throttle valve completely open 1.7 - 4.2
If no failures are detected during checks replace the throttle valve sensor, otherwise proceed with step
3.
3.
Check the cable harness and the connector between the EFI ECU control unit and the throttle valve
sensor (lines VC, VTH, E2) for interrupted or short-circuited wires.
For the Model EURO 4, the circuits in question comprise the cable harnesses downstream and up-
stream the DRACO control unit and on the DRACO itself.
If there are no failures, check or replace the EFI ECU control unit.
Checking procedure
If the diagnostic failure codes P0110 (intake air temperature circuit malfunction), P0115
(engine coolant temperature circuit malfunction), and P0120 (Throttle/pedal position sensor
A7 switch malfunction) are generated at the same time, the Sensor ground E2 could be
open.
IS - 465
P0130 - Malfunzionamento circuito sensore ossigeno (sensore 1)
KEY:
1. Switch
2. 60A fuse F/L
3. Main relay
4. Fuel pump relay
5. Battery
6. Fuel pump
7. Front part
8. Rear part
9. Rear O2 sensor heating
10. Rear O2 sensor
11. Front O2 sensor heating
12. Front O2 sensor
13. 15A EFI fuse No. 1
IS - 466
Circuit description
The front oxygen sensor (bank 1, sensor 1) detects
the concentration of oxygen in the exhaust fumes
according to the magnitude of the electromotive
force generated Vo. When the air-fuel ratio Si
turns richer than the stoichiometric ratio, a greater
electromotive force is applied to the electronic con-
trol unit (about 1 volt). Vice versa, when the ratio
turns leaner than the stoichiometric ratio, a smaller
electromotive force is applied to the electronic con-
trol unit (about O volt). In this way, the electronic
control unit determines if the air-fuel ratio Si is rich
or lean. The injection time is checked according to
this assessment.
KEY:
Si Air-fuel ratio
Vo Increasing voltage
Conditions
Affected area
P0130 If the following conditions (a) and (b) continue
to be detected after a certain period:
a) after warming up the engine, the signal ar-
riving from the oxygen sensor remains con-
stantly in the non-rich status, without turning
rich not even once.
b) The oxygen sensor output voltage remains
at 0.3 V or more, or at 0.6 V or less while run-
ning at idle speed after the engine has been
warmed up (detection logic with 2 interven-
tions).
- Air intake system
- Fuel pressure
- Open circuit or short circuit in the heated oxy-
gen sensor circuit
- Oxygen sensor heated
By using the diagnostic tester DS-21 or the OBD II general scanning device, confirm that the oxygen
sensor output voltage (bank 1, sensor 1) is equal to 0.1V or less. It is very probable that the oxygen
sensor circuit (bank 1, sensor 1) is open or short-circuited.
Functional check
through the special tool. Set the ignition switch and the tester main switch to ON. Set the tester to
"Continuous monitoring results" of the CARB mode.
IS - 467
2. Start the engine. Warm up the engine for more than five minutes, until the engine cooling water
temperature reaches 90C or a higher value.
3. Run the engine at a speed of 2500 - 3000 rpm for about three minutes.
4. After one minute the engine is running at idle, press the F1 key on the tester. Check that the diagnostic
failure code P0130 is generated.
CAUTION
- Strictly follow the described procedure or the malfunction can not be detected.
- If there is no diagnostic tester DS-21 available, set the ignition switch to OFF after carrying out steps
from 2 to 4, then repeat steps from 2 to 4.
Checking procedure
Read the frozen image data using the diagnostic
tester DS-21 or OBD II general scanning device.
As frozen image data record the engine conditions
at the moment the defect is detected, these data
are useful to determine during the troubleshooting
phase, if at the moment of failure checking, the
vehicle was working or at standstill, if the engine
was hot or not, if the air/fuel ratio was lean or rich
etc.
1.
IS - 468
If other diagnostic failure codes are detected be-
sides P0130, proceed with the relevant diagnostic
failure code diagram, otherwise jump to step 2.
oxygen sensor and the electronic control unit.
With the ignition switch set to OFF, set
the special tool (sub-wiring harness).
Disconnect the oxygen sensor connec-
tor.
Check the cable harness and the con-
nector for interrupted or short-circuited
wires. Check if there are interrupted or
short-circuited wires between the con-
nector X28 of the oxygen sensor on the
cable harness side and the terminal 75
of the special tool, repair or replace the
cable harness or the connector, if nec-
essary.
3. Checking the oxygen sensor output voltage while running at idle.
Connect the oxygen sensor and connectors of the special tool, respectively.
Connect the diagnostic tester DS-21 to the Data Link Connector by means of the special
tool.
Specific tooling
Let the engine run at 2500 rpm for
about 90 seconds.
Set the tester main switch to ON to
read the oxygen sensor output voltage
while running at idle.
If voltage varies repeatedly between a voltage be-
low 0.3V and above 0.6V, jump to step 10.
IS - 469
4. Irregular ignition check
Check if an irregular ignition is detected by moni-
toring the diagnostic failure code and the data list,
troubleshoot the irregular ignition failure, if neces-
sary. (diagnostic failure code P0300, P0301-304).
5. Air intake system check
Check the following options:
- Checking the engine oil level indicator, oil cap
and PVC pipe, also inspecting that the latter is not
disconnected.
- Checking there is no disconnection, loosening or
cracking in the air intake system parts between the
cylinder head and the throttle body. Repair or re-
place the intake system, if necessary.
6.
Check and repair the fuel pump, the fuel pressure
regulator, fuel duct and filter, if necessary.
7.
Check the injector for correct operation and re-
place, if necessary.
8.
Check there are no gas leaks in the exhaust sys-
tem, replace or repair the defective parts, if nec-
essary.
9.
Checking the oxygen sensor unit output voltage.
Warm up the engine completely.
tor with the ignition switch set to OFF.
Connect a voltmeter to the oxygen sen-
sor connector terminal.
Keep the engine rotation speed at 2000 rpm for 3 minutes.
Now, check that the value indicated on the voltmeter matches the value specified. Specified value:
If the voltmeter indicates an output voltage of 0.2V or more at least once, check or replace the engine
electronic control unit, otherwise replace the oxygen sensor (bank 1, sensor 1).
10.
Repeat the functional check.
IS - 470
11.
If the diagnostic failure code P0130 is detected again, check or replace the engine electronic control
unit.
12.
If the vehicle has run out of fuel before, the diagnostic failure code P0130 is caused by fuel exhaustion,
otherwise check the malfunction that is detected intermittently or due to false contact.
P0133 - Risposta lenta circuito sensore ossigeno (Sensore 1)
KEY:
1. Switch
2. 60A fuse F/L
3. Main relay
4. Fuel pump relay
5. Battery
6. Fuel pump
7. Front part
8. Rear part
10. Rear O2 sensor
12. Front O2 sensor
IS - 471
Circuit description
Refer to the diagnostic failure code P0130 (Oxygen sensor circuit malfunction (Bank 1 sensor 1)
Conditions
Affected area
P0133 The response time so that the oxygen sensor
output voltage changes from rich to lean, or
from lean to rich, exceeds a certain period
while the engine runs at idle speed after it has
been warmed up (detection logic with 2 inter-
ventions)
- Air intake system - Fuel pressure
- Open circuit or short circuit in the heated oxy-
gen sensor circuit
- Oxygen sensor heated
SENSOR 1 REFERS TO THE SENSOR CLOSURE ON THE ENGINE BLOCK.
READ THE FROZEN IMAGE DATA USING THE DIAGNOSTIC TESTER DS-21 OR OBD II GENERAL
SCANNING DEVICE. AS FROZEN IMAGE DATA RECORD THE ENGINE CONDITIONS AT THE
MOMENT THE DEFECT IS DETECTED, THESE DATA ARE USEFUL TO DETERMINE DURING THE
TROUBLESHOOTING PHASE, IF AT THE MOMENT OF FAILURE CHECKING, THE VEHICLE WAS
WORKING OR AT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IF THE AIR/FUEL RATIO
WAS LEAN OR RICH ETC.
CHECKING PROCEDURE
1. If other codes are generated besides the code
P0130, proceed with the relevant diagnostic failure
code diagram.
oxygen sensor and the electronic control unit.
tor.
Refer to sect. ''Checking wires and
connectors'', check the cable harness
and the connector for interrupted or
short-circuited wires.
Check if there are interrupted or short-circuited ca-
bles between the X28 connector of the oxygen
sensor on the cable harness side and the terminal
IS - 472
75 of the special tool. Repair and replace the cable
harness or the connector, if necessary.
tool.
Specific tooling
Set all the accessory switches to OFF.
Warm up the engine at 2500 rpm, until
the radiator fan completes one turn.
Set the tester main switch to ON.
Read the oxygen sensor output voltage with the
engine running at idle and the radiator fan stop-
ped.
If voltage varies repeatedly between a voltage be-
low 0.32V and above 0.58V, jump to step 8.
- Checking the engine oil level indicator, oil cap
and PVC pipe, also inspecting that the latter is not
disconnected.
- Checking there is no disconnection, loosening or
cracking in the air intake system parts between the
cylinder head and the throttle body. Repair or re-
place the intake system, if necessary.
5.
Checking the fuel pressure and repair the fuel
pump, fuel pressure regulator, fuel pipe and filter,
if necessary.
6.
Checking the injector injection. Check for proper
operation and replace the injector, if necessary.
7. Checking the oxygen sensor unit output
voltage
IS - 473
sor connector terminal A
Keep the engine rotation speed for 3
minutes at 2000 rpm. Now, check if the
value indicated in the voltmeter match-
es the specified value.
If the voltmeter indicates an output voltage of 0.2V or more at least once, check or replace the engine
electronic control unit, otherwise replace the oxygen sensor (bank 1, sensor 1).
8.
Repeat the functional check. (Refer to the diagnostic failure code diagram P0130).
9.
If code P0133 is detected again, check or replace the electronic control unit, otherwise check the mal-
function that is detected intermittently or due to false contact.
P0135 (Sensore1) P0141 (Sensore2) - Malfunzionamento circuito
riscaldatore sensore ossigeno
KEY:
1. Starter switch
2. 60A fuse F/L
3. Main relay
IS - 474
4. Fuel pump relay
5. Battery
6. Fuel pump
7. Front part
8. Rear part
10. Rear O2 sensor
12. Front O2 sensor
Circuit description
Refer to the diagnostic failure code P0130 (Oxygen sensor circuit malfunction (bank 1 sensor 1)
Conditions
Affected area
P0135
P0141
With battery voltage above 7.5 V and heater
terminal voltage of the electronic control unit
above 1.0 V while the heater is on, or below 7.5
V while the heater is off: (detection logic with 2
interventions)
- Interrupted or short-circuited wire in the oxy-
gen sensor heater
1. Checking the electronic control unit output
voltage
Set the special tool (sub-wiring har-
ness).
Measure voltage between connectors
20 OXH1, 50 OXH2 and the body
ground according to the following con-
ditions.
Measurement conditions
With ignition switch set to ON After the engine start-up
Front oxygen sensor Battery voltage Below 1V immediately after
IS - 475
Measurement conditions
rear oxygen sensor Battery voltage Below 1V only after about
three minutes
If failures are detected during checks, inspect or replace the electronic control unit.
2. Oxygen sensor check
Check resistance of the front and rear oxygen sensor heater; replace the oxygen sensor, if necessary,
otherwise check or replace the cable harness or the connector between the main relay and the oxygen
sensor and the engine electronic control unit.
P0136 - Malfunzionamento circuito sensore ossigeno (Sensore 2)
KEY:
1. General switch
2. 60A fuse F/L
3. Main relay
4. Fuel pump relay
5. Battery
6. Fuel pump
7. Front part
8. Rear part
10. Rear O2 sensor
IS - 476
12. Front O2 sensor
Refer to the diagnostic failure code P0130 (oxygen sensor circuit malfunction (bank 1 sensor 1)
Conditions
Affected area
P0136 The voltage output of the heated oxygen sen-
sor remains at 0.4V or more, or at 0.5V or less,
when the vehicle is run at 100 km/h or more
after the engine has been warmed up
(detection logic with 2 interventions)
- Interrupted or short-circuited wire in the heat-
ed oxygen sensor circuit.
- Oxygen sensor
SENSOR 2 REFERS TO THE SENSOR THAT IS MORE DETACHED FROM THE ENGINE BLOCK.
Functional check
"Continuous monitoring results" of the CARB mode.
2. Start the engine. With all the switches set to OFF, warm up the engine until the engine coolant
3. Accelerate the vehicle up to a speed of 50 km/h or more with range 2 in case of vehicles with automatic
transmission; with the 1st - 2nd gear in case of vehicles with manual transmission. Run the vehicle at
this speed for at least 40 seconds.
4. Under these conditions, remove the foot from the accelerator so as to decelerate the vehicle. Run
the engine at idle speed.
5. After one minute the engine is running at idle, press the F1 key on the tester. Check that the diagnostic
failure code P0136 is generated.
- STRICTLY FOLLOW THE DESCRIBED PROCEDURE OR THE MALFUNCTION CAN NOT BE DE-
TECTED.
- IF THERE IS NO DIAGNOSTIC TESTER DS-21 AVAILABLE, SET THE IGNITION SWITCH TO OFF
AFTER CARRYING OUT STEPS FROM 2 TO 5, THEN REPEAT THE PREVIOUS STEPS.
- Perform the confirmation test according to the described procedure in sect. Using the OBDII general
scanning device or diagnostic tester DS-21.
IS - 477
Checking procedure
1. If other diagnostic failure codes are detected besides P0136, proceed with the relevant step of the
diagnostic failure code diagram.
2. Checking the cable harness between the oxygen sensor and the electronic control unit.
With the ignition switch set to OFF, set the special tool (sub-wiring harness). The special
tool connectors on the electronic control unit side must be disconnected.
Disconnect the oxygen sensor connector.
Check the cable harness and the connector for interrupted or short-circuited wires.
Check if there are interrupted or short-circuited cables between the connector XJ5 of the oxygen sensor
on the cable harness side and the terminal 74 of the special tool. Repair and replace the cable harness
or the connector, if necessary.
READ THE FROZEN IMAGE DATA USING THE DIAGNOS-
TIC TESTER DS-21 OR OBD II GENERAL SCANNING DE-
VICE. AS FROZEN IMAGE DATA RECORD THE ENGINE
CONDITIONS AT THE MOMENT THE DEFECT IS DETEC-
TED, THESE DATA ARE USEFUL TO DETERMINE DURING
THE TROUBLESHOOTING PHASE, IF AT THE MOMENT OF
FAILURE CHECKING, THE VEHICLE WAS WORKING OR
AT STANDSTILL, IF THE ENGINE WAS HOT OR NOT, IF
THE AIR/FUEL RATIO WAS LEAN OR RICH ETC.
IS - 478
tool.
Specific tooling
Warm up the engine.
Set the tester main switch to ON. Run
the engine at 4000 rpm for three mi-
nutes, pushing accelerator pedal.
Then, remove the foot from the pedal
and run the engine at idle speed.
Read the oxygen sensor output volt-
age among previous steps.
Voltage must be 0.4 V or less, and 0.55 V or more,
respectively, at least once. Otherwise, check the
malfunction that is detected intermittently or bad
contacts.
voltage
The voltmeter must indicate an output voltage of
0.2V or more at least once, if below, check or re-
place the engine electronic control unit, otherwise
replace the oxygen sensor (bank 1, sensor 2).
P0141 - Circuito riscaldatore sensore ossigeno secondario
Pagina Manuale VTL
P0135 (Sensore1) P0141 (Sensore2) - Malfunzionamento circuito riscaldatore sensore ossigeno
IS - 479
P0171 - Sistema troppo povero / P0172 - Sistema troppo ricco (taglio
combustibile)
KEY:
1. Ignition switch.
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
11. Front O2 sensor
12. Injector
Circuit description
Fuel trim means the return offset value which compensates the basic injection time. There are two
modes of fuel trim: short term and long term fuel trim.
Short term fuel trim is a short term fuel compensation which must occur to keep the air-fuel ratio at the
level of the stoichiometric air-fuel ratio. The signal arriving from the oxygen sensor indicates if the current
IS - 480
air-fuel ratio is rich or lean with respect to the stoichiometric air-fuel ratio. Therefore, if the air-fuel ratio
is rich, the fuel injection decreases. Vice versa, if the air-fuel ratio is lean, the fuel injection increases.
Long term fuel trim is a fuel compensation which is detected in a long term period to offset a constant
drift of short term fuel trim with respect to the central value, caused by the intrinsic characteristics of
the vehicle, due to long term use or a variation of the operative environment.
If the total of the short and long term fuel trim exceeds a certain value, and if it turns rich or lean, the
system turns the warning light MIL on to indicate it as a malfunction.
Diagnostic failure code
No.
Diagnostic failure code detection
conditions
Affected area
P0171 If the following conditions are detected
during the execution of the air-fuel return
after warming up the engine:
- Air-fuel too lean: The total of fuel trim
(total of short term and long term fuel trim)
exceeds the set value
- Interrupted or short-circuited wire in the
oxygen sensor circuit.
- Oxygen sensor malfunction
- Vacuum switching valve for vapour
bleeding
P0172 - Air-fuel too rich: (the total of fuel trim is
lower than the set value). (detection logic
with 2 interventions)
IF THE VEHICLE HAS RUN OUT OF FUEL, THE AIR-FUEL RATIO TURNS LEAN, THEREFORE,
THE DIAGNOSTIC FAILURE CODE P0171 IS INDICATED.
Functional check
With the ignition switch set to OFF, connect the diagnostic tester DS-21 to the Data Link
Connector through the special tool. Set the ignition switch and the tester main switch to ON.
Set the tester to "Continuous monitoring results" of the CARB mode.
Start the engine. Warm up the engine for more than five minutes, until the engine cooling
water temperature reaches 90C or a higher value.
Run the vehicle for more than five minutes at a speed of 70 km/h after engaging the 5th gear
or in range D.
After one minute the engine is running at idle, press the F1 key on the tester. Check if the
diagnostic failure code P0171/0172 is indicated
IS - 481
.
- STRICTLY FOLLOW THE DESCRIBED PROCEDURE OR THE MALFUNCTION CAN NOT BE DE-
TECTED.
AFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS.
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CARRY OUT THE CONFIRMATION TEST ACCORDING TO THE INSTRUCTIONS INDICATED IN
THE SECTION " USING THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC TESTER
DS-21 " .
Using the diagnostic tester DS-21 or OBD II general scanning device
If other diagnostic failure codes are detected besides P0172 or P0172 proceed with the relevant diag-
nostic failure code diagram.
Checking the engine oil level indicator, oil cap and PVC pipe, also inspecting that the latter
is not disconnected.
Checking there is no disconnection, loosening or cracking in the air intake system parts
between the cylinder head and the throttle body. Repair or replace the intake system, if
necessary.
3. Checking the injector injection.
Check for proper operation and replace the injector, if necessary.
4. Checking the vacuum switching valve for vapour bleeding.
Replace the vacuum switching valve for vapour bleeding, if necessary.
5. Checking the engine water temperature sensor operation.
Replace the engine coolant temperature sensor, if necessary.
6. MAP sensor check.
Replace the MAP sensor, if necessary.
7. Fuel pressure check.
Check and repair the fuel pump, the fuel pressure regulator, fuel duct and filter, if necessary.
IS - 482
8. Gas leakage check in the exhaust system
Check there are no gas leaks, repair and replace,
if necessary.
oxygen sensor and the electronic control unit
The special tool connectors on the
electronic control unit side must be dis-
connected.
tor.
Check the cable harness and the con-
nector for interrupted or short-circuited
wires.
Check if there are interrupted or short-circuited
wires between the connector X28 of the oxygen
sensor on the cable harness side and the terminal
75 of the special tool, repair or replace the cable
harness or the connector, if necessary.
10. Checking the oxygen sensor output volt-
age while running at idle
Connect the oxygen sensor and spe-
cial tool connectors, respectively.
Connect the diagnostic tester DS-21 to
the Data Link Connector by means of
the special tool.
Specific tooling
IS - 483
Let the engine run at 2500 rpm for
about 90 seconds.
Set the tester main switch to ON to
read the oxygen sensor output voltage
while running at idle. Specified value: if
voltage varies repeatedly between a
voltage below 0.3V and above 0.6V,
jump to step 12.
voltage
If the voltmeter does not indicate an output voltage
equal to 0.2V or more at least once, check or re-
place the engine electronic control unit, otherwise
replace the oxygen sensor (bank 1, sensor 1).
12.
Confirm the driving configuration.
13.
If the diagnostic failure code P0171 or P0172 is indicated again, check or replace the engine electronic
control unit.
14.
If the vehicle has run out of fuel before, the diagnostic failure code P0171 is determined by fuel ex-
haustion. Alternatively, check the malfunction that is detected intermittently or due to false contact.
Without using the diagnostic tester DS-21 or OBD II general scanning device
1.
If other diagnostic failure codes are detected besides P0172 or P0172 proceed with the relevant diag-
nostic failure code diagram.
IS - 484
Checking the engine oil level indicator, oil cap and PVC pipe, also inspecting that the latter
is not disconnected.
Checking there is no disconnection, loosening or cracking in the air intake system parts
between the cylinder head and the throttle body.
Check and repair the fuel pump, fuel duct and filter, if necessary.
4. Injector check
Check for proper operation and replace the injector, if necessary.
5. Checking the engine water temperature sensor operation
Replace the engine coolant temperature sensor, if necessary.
6. MAP sensor check
(see troubleshooting of diagnostic failure code P0105) Replace the MAP sensor, if necessary.
7.
After fitting an oxygen sensor operating properly (bank 1, sensor 1), confirm the driving configuration.
If the diagnostic failure code P0171 or P0172 is not indicated. replace the oxygen sensor (bank 1, sensor
1) previously fitted on the vehicle, otherwise check or replace the engine electronic control unit.
P0172 - Carburazione ricca
Pagina Manuale VTL
P0171 - Sistema troppo povero / P0172 - Sistema troppo ricco (taglio combustibile)
P0300 - Mancata accensione casuale di pi cilindri
Pagina Manuale VTL
P0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/monocilindro/cilindro multiplo/cil-
indro1/cilindro2/
P0301 - Mancata accensione cilindro 1
Pagina Manuale VTL
P0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/monocilindro/cilindro multiplo/cil-
indro1/cilindro2/
P0314-P0300-P0301-P0302-P0303-P0304 - Accensione irregolare/
monocilindro/cilindro multiplo/cilindro1/cilindro2/
Failure code Description
P0314 Single-cylinder irregular ignition (cylinder not specified)
P0300 Random/multiple cylinder irregular ignition detected
P0301 Irregular ignition detected - cylinder 1
IS - 485
Confirming the driving configuration
1. Connect the diagnostic tester DS-21 or OBD II general scanning device with the ignition switch set
to OFF.
2. Record the diagnostic failure code and the frozen image data with the ignition switch set to ON.
3. Clear the diagnostic failure code.
4. Use the diagnostic tester DS-21 or OBD II general scanning device to set "Continuous monitoring
results" of the CARB mode.
5. Ride the vehicle at a constant speed many times, with load and related parameters indicated by
ENGINE RPM.CALC LOAD in the frozen image data or MISFIRE RPM, MISFIRE LOAD in the data
list. If malfunctions are detected, code P0314 is displayed (press F1 key:) If there is no diagnostic tester
DS-21 available, set the ignition switch to OFF after the indication is simulated for the first time. Then,
repeat the simulation process.
TO STORE THE DIAGNOSTIC FAILURE CODE RELATED TO IRREGULAR IGNITION, RUN THE
ENGINE ACCORDING TO MISFIRE RPM, MISFIRE LOAD VALUES INDICATED IN THE DATA LIST
DURING THE TIME INDICATED BELOW.
Engine speed Time
Idle speed 3 minutes 30 seconds or more
1000 rpm 3 minutes or more
2000 rpm 1 minute 30 seconds or more
3000 rpm 1 minute or more
6. Check if there is an irregular ignition by monitoring the diagnostic failure code and the frozen image
data. Then, record the data.
7. Set the ignition switch to OFF after at least 5 seconds.
WARNING
CARRY OUT THE CONFIRMATION TEST ACCORDING TO THE INSTRUCTIONS INDICATED IN
THE SECT. ''USING THE OBD II GENERAL SCANNING DEVICE OR DIAGNOSTIC TESTER DS-21''
IS - 486
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. CABLE HARNESS SIDE FUEL INJ ECTOR
11. Ignition system
12. Ignition coil
13. Spark plugs
14. 20A engine
15. Injector
Circuit description
Irregular ignition
- The ignition system detects the ionic current according to the fuel pressure. The ionic current turns
into voltage that is input in the Electronic Control Unit. If the voltage value is lower than a certain value,
the Electronic Control Unit considers it an irregular ignition, counting the number of events. When the
IS - 487
number of irregular ignitions reaches or exceeds the digit which indicates that the engine is damaged,
the malfunction warning light MIL turns on. If an irregular ignition is detected and the number of events
is such that under riding conditions an overheating of the catalytic converter can be detected, the mal-
function warning light MIL starts flashing.
Code Code detection conditions Affected area
P0314
P0300
In the course of 400 or 2,000 ignitions, no
firing of random/multiple cylinders has
been detected.
- Ignition system (ignition spark plug unit,
etc.)
- Ion system (ignition spark plug unit, etc.)
- Injector
- Fuel pressure
- Valve clearance
- Valve adjustment
- Pressure sensor
- Interrupted or short-circuited wire in en-
gine cables
- Engine Electronic Control unit
P0301
P0302
P0303
P0304
On 400 engine ignitions, irregular igni-
tions are detected which can cause the
overheating of the catalytic converter (the
malfunction warning light starts to flash)
On 2,000 engine ignitions, irregular igni-
tions are detected which cause a degra-
dation of emissions (detection logic with
2 interventions)
N.B.
IF 2 OR MORE CODES RELATED TO A CYLINDER WITH IRREGULAR IGNITION ARE RECORDED
IN SUCCESSION, AS LONG AS RANDOM/MULTIPLE CYLINDER IRREGULAR IGNITION CODES
ARE NOT RECORDED, IT MEANS THAT THE IRREGULAR IGNITION IS DETECTED AND RE-
CORDED AT DIFFERENT TIMES. IF ONE OR MORE CODES COMPRISED WITHIN P0301 AND
P0304 ARE INDICATED, THE CODE P0314 IS CERTAINLY STORED. HOWEVER, THE CODE
P0314 IS DISPLAYED ONLY WHEN THE FUNCTION " CONTINUOUS MONITORING RESULTS" OF
THE CARB MODE IS USED.
P0314 Single-cylinder irregular ignition (cylinder not specified)
P0300 Random/multiple cylinder irregular ignition detected
Checking procedure
In case that besides the irregular ignition code other diagnostic failure codes are stored at
the same time, first of all, detect relative failures.
IS - 488
If the vehicle is brought to the workshop without the irregular ignition check, this can be
confirmed by reproducing the frozen image data conditions. Besides, once the repair is
finished, confirm that conditions for an irregular ignition have not been detected (see con-
firming the driving configuration).
When the value of SHORT FT or LONG FT in the frozen image data is approx. 20%, it is
probable that the air-fuel ratio tends to RICH (-20% or less) or LEAN (+20% or more).
When the COOLANT TEMP value in the frozen image data is lower than 80C (176), an
irregular ignition can be detected only during the warm-up phase.
If the irregular ignition can not be reproduced, this can be due to riding with low fuel, to the
inadequate use of fuel, dirty spark plug, etc.
An interrupted wire detected at the input line of the ionic signal between the ignition spark
plug unit and the Electronic Control Unit of the Fuel Injection, can be considered an irregular
ignition.
1. Engine compartment visual check
Check the cable harness and connec-
tor connections.
Check that suction, bleeding, fuel and
other pipes are not disconnected or
broken, repair or replace, if necessary,
then confirm there is no irregular igni-
tion.
2. Check the spark plug and spark of the cyl-
inder with irregular ignition
relay block. Remove the ignition coils
and the spark plugs (cylinders with ir-
regular ignition).
Fit the spark plug on the ignition coil.
Connect the ignition coil connector to
the coil.
Now, start the engine and check if the
spark plug releases sparks.
Otherwise, check according the proce-
dure described for spark plugs.
IS - 489
Replace the spark plug or check the ignition sys-
tem and the ionic system.
(See troubleshooting of Diagnostic Failure Code
P 1300).
DO NOT USE SPARK PLUGS DIFFERENT FROM THOSE
RECOMMENDED.
3. Checking the output signal of the cylinder
injector electronic control unit with irregular
ignition
set
ness).
measure voltage between the injector
connector terminal, in which the irreg-
ular ignition is detected, connectors 27
up to 24, and the body ground. Speci-
fied value: battery voltage
Watch the injector wave shape with an
oscilloscope (reference).
Check the wave shape of the voltage among con-
nectors 27 up to 24 and 82 E01, with the engine at
idle speed.
If failures are detected during checks proceed with
step 6.
4. Checking the defective cylinder injector.
Disconnect the connector of the defec-
tive cylinder injector.
Measure resistance between the injec-
tor terminals Specified value: 12.5_
mm at 20C.
If no failures are detected while checking, replace
the injector.
IS - 490
5. Check the cable harness between the injec-
tor and the electronic control unit
from the fuel injection electronic control
unit (with the ignition switch set to
OFF).
Refer to sect. ''Checking wires and
connectors'', check the cable harness
and the connector for interrupted or
short-circuited wires.
- X51 injector connector #1 on the cable harness
side. Special tool connector 27
side - special tool connector 24 , repair or replace
the cable harness or the connector, if necessary,
otherwise check the malfunction that is detected
intermittently or that there are no bad contacts.
6. Ionic system check
(see troubleshooting of Diagnostic Failure Code P 1300), repair or replace, if necessary.
Check and repair the fuel pump, the fuel pressure regulator, fuel duct and filter, if necessary.
8. Check the injection injector.
Replace the injector, if necessary.
9. Check the manifold absolute pressure sensor, (See troubleshooting of Diagnostic Failure
Code P0105).
Replace the manifold absolute pressure sensor.
10. Check the engine water temperature sensor, (see troubleshooting of Diagnostic Failure Code
P0116).
Replace the engine coolant temperature sensor, otherwise check the compression pressure, valve
clearance and distribution timing, if necessary.
IS - 491
P0135 - Malfunzionamento circuito sensore posizione albero a camme
Checking procedure
Read the frozen image data using the diagnostic
tester DS-21 or OBD II general scanning device.
As frozen image data record the engine conditions
at the moment the defect is detected, these data
are useful to determine during the troubleshooting
phase, if at the moment of failure checking, the
vehicle was working or at standstill, if the engine
was hot or not, if the air/fuel ratio was lean or rich
etc.
1. Checking the cam angle sensor circuit re-
sistance
ness). Connector A of the tool must
remain disconnected from the Elec-
tronic Control Unit connector B.
2. Set the ignition switch to OFF and measure resistance between terminals of the special tool 22 -
52 (N2 +N2).
Characteristic
specified value
from 205 to 255 Ohm at 20C
Signal control
Check with an oscilloscope.
a. Connect connector A to the electronic control
unit.
b. Start the engine and run it at idle speed.
c. Connect the positive (+) and negative (-) probe
of an oscilloscope to the special tool connector
terminals from 22 to 23, respectively.
IS - 492
d. If the wave shapes shown in the figure on the
right are detected, the cam angle sensor circuit
operates properly.
N.B.
THE WAVE SHAPE DETECTED WITH THE VEHICLE RUN-
NING BECOMES WIDER WITH RESPECT TO THAT ONE
DETECTED WITH THE ENGINE AT IDLE. IF SO, PASS TO
STEP 4.
2. Cam angle sensor check
Remove the engine service opening cover.
Disconnect the connector lock and remove the cam angle sensor connector.
With an ohmmeter, measure resistance between terminals.
Characteristic
specified value
Replace the cam angle sensor, if necessary.
3. Check there are no interrupted or short-
circuited wires in the cable harness and the
connector between the engine electronic con-
trol unit and the cam angle sensor
Repair or replace the cable harness or the con-
nector, otherwise check the malfunction that is
detected intermittently or bad contacts.
4. Check the sensor fitting conditions and the
signalling rotor teeth status
Check there are no free spaces, the sensor is no
loosened, teeth are not deformed, there is no rust,
foreign bodies, etc. Tighten the sensor, if neces-
sary or replace the signalling rotor.
IS - 493
5. Check the starter motor signal
Connect connector A to the electronic
control unit.
Measure voltage between terminals 68
and 23 of the special tool connector
(STA-E1) during engine start-up.
Specified value: battery voltage - repair
or replace the cable harness or the
connector (between the engine elec-
tronic control unit - ignition switch), oth-
erwise check or replace the electronic
control unit.
KEY:
1. AM 60 A
2. Ignition switch
3. Battery
IS - 494
4. Starter motor
6. Cam angle sensor (sensor n+1)
Circuit description
Cam angle sensor (NE signal) comprises a single rotor and a pickup coil. The NE signal rotor is equipped
with "4+1" teeth and fitted on the cylinder head so that the rotor is directly connected to the camshaft.
The NE sensor produces five signals (from which one is used to differentiate cylinders) every two engine
revs. The electronic control unit measures the crankshaft angle according to the signal N2+ and the
engine speed with NE signals.
Conditions
Affected area
P0335 No signal sent from the cam angle sensor to
the engine electronic control unit during the ac-
tivation with the starter motor
- Interrupted or short-circuited wire in the cam
angle sensor
- Cam angle sensor
- Signalling rotor
- Starter motor
P0420 - Catalizzatore efficienza inferiore
KEY:
IS - 495
1. General switch
2. 60A fuse F/L
3. Main relay
4. Fuel pump relay
5. Battery
6. Fuel pump
7. Front part
8. Rear part
10. Rear O2 sensor
12. Front O2 sensor
Circuit description
The electronic control unit monitors the concentration of oxygen in the exhaust fumes which passes
through the three-way catalytic converter, with the rear oxygen sensor. If the catalytic converter works
properly, the variable rear oxygen sensor output voltage is slower than the front oxygen sensor output
voltage. However, if the wave shape variation of the front and rear sensor output is equal, it means that
the catalytic converter performance declines.
Conditions
Affected area
P0420 With wave shapes of front as well as rear oxy-
gen sensors which indicate the same frequen-
cy while running the vehicle at a predetermined
speed, with the engine revs within a pre-set
range: (detection logic with 2 interventions)
- Three-way catalytic converter
- Interrupted or short-circuited wire in the oxy-
gen sensor circuit.
- Oxygen sensor
1. Set the ignition switch set to OFF, and connect the diagnostic tester DS-21 to the Data Link Connector
"continuous monitoring results" of the CARB mode.
2. Start the engine. With all the switches set to OFF, warm up the engine until the engine coolant
3. Run the engine at a constant speed of 50 km/h for about five minutes (4th gear, in case of vehicles
with manual transmission; range D, in case of vehicles with automatic transmission).
4. After one minute the engine is running at idle, press the F1 key on the tester. Check that the suitable
diagnostic code PD420 is generated.
IS - 496
- STRICTLY OBSERVE THE TESTING CONDITIONS TO DETECT THE MALFUNCTION.
AFTER CARRYING OUT STEPS FROM 2 TO 4, THEN REPEAT THESE STEPS.
<?xml:namespace prefix =or ns ="urn:schemas-microsoft-com:office:office" />
Checking procedure
Read the frozen image data using the diagnostic tester DS-21 or OBD II general scanning device. As
frozen image data record the engine conditions at the moment the defect is detected, these data are
useful to determine during the troubleshooting phase, if at the moment of failure checking, the vehicle
was working or at standstill, if the engine was hot or not, if the air/fuel ratio was lean or rich etc.
1. Other codes besides P0420 are indicated; consult the relevant diagram of diagnostic failure.
2. Front oxygen sensor checking
(bench 1, sensor 1).
(See troubleshooting of diagnostic failure code P0130). Repair or replace, if necessary.
3. Rear oxygen sensor checking
(bench 1, sensor 2).
(See troubleshooting of diagnostic failure code P0136). Repair or replace, if necessary.
4. Validate the driving configuration.
5. If the failure code P0420 has not been indicated again, check the failure that is detected with inter-
mittence or due to a bad contact, otherwise replace the three-way catalytic converter.
IS - 497
P0443 - Malfunzionamento circuito Valvola di controllo spurgo_Sistema di
controllo delle emissioni evaporative
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Injector
11. EFI ECU
Circuit description
When working conditions for vapour emission bleeding are fulfilled, the electronic control unit checks
the operation of the vacuum switching valve for bleeding vapour emissions, introducing them in the
combustion chamber.
IS - 498
KEY:
1. Throttle body
2. ECU
3. VSV for EVAP
4. Atmosphere
5. Combustion chamber
6. Active carbon filter
7. Fuel tank
Conditions
Affected area
P0443 If there are interrupted or short-circuited wires
in the vapour vacuum switching valve circuit,
and with the working conditions of the vapour
emission bleeding system fulfilled: (detection
logic with 2 interventions)
- Interrupted or short-circuited wires in the va-
pour vacuum switching valve circuit
- Vapour vacuum switching valve
Checking procedure
IS - 499
Using the diagnostic tester DS-21
1. Checking the operation of the vapour bleed-
ing control system
special tool.
Specific tooling
Disconnect the pipe that goes from the
active carbon filter to the vacuum
switching valve.
Set the ignition switch to ON and press
the tester main switch. Clear the diag-
nostic failure code. Select the "VSV
Bleeding" from the "Actuator control".
When switching ON and OFF, check
the operation of the vacuum switching
valve for bleeding. VSV OFF, no air
continuity when air is blown into the
pipe. VSV ON, air continuity when air
is blown into the pipe.
KEY:
1. Bleeding side
2. Air blown
3. Atmospheric hole
4. Tank side
2. Checking the bleeding pipe and passage
"Unlock" the vacuum switching valve to
return the bleeding valve to original
working conditions.
Start the engine and let it run.
Disconnect the pipe that goes from the
vacuum switching valve to the inlet
manifold.
IS - 500
Put a finger on the removed pipe.
Check that a negative pressure is ap-
plied. Specifications: It is necessary to
apply a negative pressure.
Check there are no leaks, narrowing,
bending on pipes and that they are not
damaged. Clean, repair or replace
connections, if necessary.
KEY:
1. Vapour vacuum switching valve
2. Bleeding pipe
3. Active carbon filter (Canister).
4. Bleeding pipe
5. Throttle body
3. Check the power supply voltage of the vac-
uum switching valve for bleeding.
Set the tester main switch to ON. Set
the ignition switch to OFF.
Disconnect the vacuum switching
valve connector.
measure voltage between the cable
harness side connector #7M of the
valve and the body ground.
If there is no response, check the cable harness
and the connector between the vacuum switching
valve for bleeding and the battery, and that there
are no interrupted or short-circuited wires on the
main relay. Repair or replace, according to the
case.
Characteristic
specified value:
battery voltage.
IS - 501
4. Check the cable harness between the elec-
tronic control unit and the vacuum switching
valve for bleeding
connect the special tool (sub-wiring
harness). Do not connect the connec-
tor to the electronic control unit.
Check there are no interrupted or
short-circuited wires in the cable har-
ness and the connector. Connector
#7N on the vacuum switching valve ca-
ble harness side - connector 79, on the
PRG electronic control unit side. Re-
pair and replace the cable harness or
the connector, if necessary.
5. Checking the vacuum switching valve for bleeding
Replace the vacuum switching valve for vapour bleeding, if necessary.
6. Check the output signal of the electronic control unit
Connect the connector to the vacuum switching valve for bleeding. Connect the connector
of the special tool to the electronic control unit. Connect the pipes previously removed in the
original position.
With the engine cold and at idle speed, measure voltage between the connector 79 and 82
PRG-E01.
Characteristic
specified value:
battery voltage.
After warming up the engine (after the
fan starts working at least once), meas-
ure voltage between connectors 79
and 82 PRG-E01 for more than two mi-
nutes, pushing and holding down the
accelerator pedal.
If failures are detected during checks,
inspect the malfunction that is detected
intermittently or due to false contact,
otherwise check or replace the elec-
IS - 502
Characteristic
specified value:
the voltage must shift from 0 to 1 V within two mi-
nutes.
Without using the diagnostic tester DS-21
1. Check the output signal of the electronic control unit
Set the special tool (sub-wiring harness).
With the engine cold and at idle speed, measure voltage between connectors 79 and 82
PRG-E01.
Characteristic
specified value:
battery voltage.
After warming up the engine (after the fan starts working at least once), measure voltage
between connectors 79 and 82 PRG-E01 for more than two minutes, pushing and holding
down the accelerator pedal.
<DIV class=cnt_summary title="Testo Breve (<4000 car.)">If there is no response, check
or replace the engine electronic control unit.
Characteristic
specified value:
the voltage must shift from 0 to 1 V within two minutes.
2. Check the power supply voltage of the vacuum switching valve for bleeding.
Disconnect the vacuum switching valve connector.
With the ignition switch set to ON, measure voltage between the cable harness side con-
nector #7M of the vacuum switching valve and the body ground.
Characteristic
specified value:
battery voltage.
IS - 503
If it does not match the specified value, check the
cable harness and the connector between the vac-
uum switching valve for bleeding and the battery,
and that there are no interrupted or short-circuited
wires in the main relay. Repair or replace, accord-
ing to the case.
valve for bleeding
tor of the special tool to the electronic
control unit.
ness and the connector. Connector
#7N on the vacuum switching valve ca-
ble harness side - connector 79, on the
PRG electronic control unit side. Re-
pair and replace the cable harness or
4. Checking the vacuum switching valve for bleeding
Replace the vacuum switching valve for bleeding, otherwise check the malfunction detected intermit-
tently or due to false contact.
IS - 504
P0500 - Malfunzionamento Sensore velocit veicolo
KEY:
2. Instrument panel
3. Speedometer cable
4. Vehicle speed sensor
Circuit description
The sensor fitted inside the instrument panel has
a magnet that is turned by the speedometer cable.
The reed switch is set to ON and OFF for four times
for each speedometer revolution. It is therefore
transmitted to the electronic control unit, which de-
termines the vehicle speed according to the fre-
quency of pulse signals.
KEY:
1. Transmission and front-wheel drive
2. Instrument panel
3. ECU
IS - 505
Conditions
Affected area
P0500 The speed sensor does not transmit any signal
to the electronic control unit for a certain period
after the fuel supply is cut during the deceler-
ation phase.
- Instrument panel
- Interrupted and short-circuited wires in the
vehicle speed sensor circuit
- Vehicle speed sensor
- Vehicle electronic control unit
1. Speedometer operation check
Start the vehicle. If the speedometer does not indicate the correct vehicle speed, check the
speedometer circuit and the instrument panel (including the speedometer gear & meter ca-
ble). If the speedometer indication is normal, it means that the speedometer works regularly.
2. Check the input signal of the speed sensor to the electronic control unit
Check that voltage between terminals 37 and 17 is within the specified limits when the ve-
hicle is moving with the ignition switch set to ON.
Characteristic
specified value:
4.5 a 5.5 V per pulse signal.
If it does not match the specified value, check or
replace the engine electronic control unit.
3. Check the speed sensor (reed switch)
Remove the instrument panel
Check that there is continuity for four
times on terminals B10 and B11 of the
instrument panel, while the speedom-
eter transmission completes one revo-
lution. Check continuity two times for
each speedometer transmission revo-
IS - 506
lution. If there is no continuity, replace
the speed sensor (instrument panel).
4. Check for interrupted and short-circuited
wires in the cable harness, and in the connec-
tor between the engine control unit and the
vehicle speed sensor
Repair or replace the cable harness or the con-
nector, otherwise check the malfunction that is
detected intermittently or due to false contact.
P1105 - Malfunzionamento circuito sensore pressione barometrica
The electronic control unit is equipped with an atmospheric sensor of the same type of the MAP sensor.
Therefore, the atmospheric sensor wiring diagram is shown in the manual.
Conditions
Affected area
P1105 When the following conditions (1 and 2) are
fulfilled for certain period:
1. The AD conversion value of the atmospheric
sensor is lower than 1.6V
2. The AD conversion value of the atmospheric
sensor is equal or higher than 4.7V
Checking procedure
1. Diagnostic failure code reconfirmation
Connector through the special tool.
Specific tooling
IS - 507
Set the ignition switch and the tester
main switch to ON.
Clear the diagnostic failure code. (To perform this
operation, consult the user manual of the diagnos-
tic tester DS-21).
Set the tester main switch and then the
ignition switch to OFF.
Set the ignition switch and then the
tester main switch to ON.
Check the diagnostic failure code.
If P1105 is indicated, replace the electronic control
unit, otherwise check or replace electronic control
unit.
P1300 - Malfunzionamento sistema ione
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
IS - 508
6. Fuel pump relay
7. Battery
8. Fuel pump
9. Ignition spark plug unit wire on the cable harness side (Electronic Control Unit side)
11. Ignition spark plug unit wire on the cable harness side (ignition coil side)
12. Ignition switch wire on the cable harness side
13. Ignition coil wire on the cable harness side
14. Ignition device
15. Ignition coil
16. Spark plug
17. 20A engine fuse
Circuit description
The system detects any irregular ignitions of the engine through an ionic current which has the same
wave shapes of combustion pressure. Each time an irregular ignition is detected, no ionic current is
generated. Therefore, if input voltage on the Electronic Control Unit side is lower than a certain value,
it is assumed that an irregular ignition is detected. Considering that the ionic current detected is too
weak, it is amplified in the ignition unit.
Conditions
Affected area
P1300 During engine start-up or operation, no signal
of ionic current is sent to the engine electronic
control unit.
- Interrupted or short-circuited wires inside the
ionic system circuit
- Ignition unit
- Ignition coil (all cylinders)
- Spark plug (all cylinders)
Checking procedure
Read the frozen image data using the
diagnostic tester DS-21 or OBD II gen-
eral scanning device. As frozen image
data record the engine conditions at
the moment the defect is detected,
these data are useful to determine dur-
ing the troubleshooting phase, if at the
moment of failure checking, the vehicle
was working or at standstill, if the en-
IS - 509
gine was hot or not, if the air/fuel ratio
was lean or rich etc.
The diagnosis diagram is based on the
assumption that the engine is started
under normal conditions. If the engine
does not start, go to the Matrix table for
troubleshooting according to the mal-
function phenomenon.
When code P1300 is generated (ionic
system malfunction), the code P0300
(detecting random/multiple cylinder ir-
regular ignition) as well as codes
P0301-P0304 (detecting irregular igni-
tion of cylinders 1 to 4) can be gener-
ated at the same time.
1. Spark check
relay block.
Remove the ignition coils and the spark
plugs (all cylinders 1, 2, 3 and 4).
Fit the spark plug on the ignition coil,
connect the ignition coil connector to
the ignition coil.
Start the engine and check the spark
plug sparks.
SPARKS WILL BE CHECKED. PAY ATTENTION TO SUR-
ROUNDING INFLAMMABLE OBJECTS.
CAUTION
NEVER USE SPARK PLUGS DIFFERENT FROM THOSE
RECOMMENDED.
2. If sparks have been checked in all cylinders proceed with step 5.
If sparks are not checked in some cylinders, inspect the spark plug of cylinders where there
is no spark.
Replace the spark plug, if necessary, repeat the spark check.
If no spark plug detected, go to step 3, otherwise go to step 5.
3. Checking the ignition coil power supply voltage
With the ignition switch set to OFF, disconnect the ignition coil connector of each cylinder.
IS - 510
With the ignition switch set to ON, measure voltage between the body ground and each one
of the cable harness side connectors N05, N53, N54 and N83 of all the ignition coils.
Characteristic
Specified value
battery voltage
If failures are detected during checks proceed with
step 5.
KEY:
4. Checking the ignition coil power supply volt-
age
Check there are no interrupted or short-circuited
wires in the cable harness, connector and fuse re-
ferring to the checking of wires and connectors.
Disconnect the connectors of the igni-
tion switch and ignition unit on the Elec-
tronic Control Unit side.
- Between the ignition switch and the ignition unit
terminal B1.
- Between the ignition switch and each connector
NO5 N53 N54 and N83 of all the ignition coils.
nector, if necessary, or replace the fuse, otherwise
replace the ignition switch.
KEY:
5. Checking the ignition signal and the ionic signal
Check that ignition and ionic signals are generated by the Electronic Control Unit and input with an
oscilloscope.
IS - 511
With the ignition switch set to OFF, reset.
Specific tooling
Warm up the engine (only when the
engine can be started).
With the engine at idle speed or run-
ning, connect the (-) oscilloscope
probe to terminal 82 of the special tool;
the (+) probe to terminals 60, 59, 58
and 57 of the special tool, respectively.
Check the ignition signal of all cylin-
ders.
Specifications:
The wave shapes of the pulse must be confirmed.
As done with step 4, connect the (+)
and (-) oscilloscope probes to termi-
nals 14 ICMB and 43 IE of the special
tool, respectively, and check the ionic
signal .
Specifications:
All wave shapes must be present as shown in the
figure.
KEY:
A. For a cylinder
B. For all cylinders
If no sparks are detected and there is no wave shape of ignition signals, ionic signals, check or replace
the Electronic Control Unit.
If no sparks are detected, the wave shape of the ignition signal is present, and there is no wave shape
of the ionic signal proceed with step 10.
If sparks are detected and the wave shape of the ignition signal is present, the wave shape of the ionic
signal can be seen. Proceed with step 6.
6. Checking the cable harness between the Electronic Control Unit and the ignition unit.
Connect the special tool connector of Electronic Control Unit of the Electronic Fuel Injection.
Disconnect the ignition unit connector on the Electronic Control Unit side.
IS - 512
Check there are no interrupted or short-circuited wires in the cable harness and connector.
- Terminal 14 of the special tool.
- Input/Output terminal of the ignition unit on the cable harness side, repair or replace the cable harness
or the connector, if necessary.
7. Checking the cable harness between the ig-
nition unit and ignition coil
Disconnect the side connector of the
ignition coil of the ignition unit C.
Disconnect the connector of each igni-
tion coil D.
- Terminal I/C on the cable harness side of the ig-
nition unit
- Terminals #LI, #L2, #L3, #L4 on the cable har-
ness side of each ignition coil.
8. Ignition unit check
Replace the ignition unit, if necessary
9. Checking the ignition unit ground circuit
Measure continuity between engine ground and terminals G1 and G2 on the cable harness
side of the ignition unit E.
Characteristic
specified value:
signs of continuity.
If failures are detected during checks replace the
ignition coil (all the cylinders), otherwise repair or
replace the cable harness or the connector.
IS - 513
ignition unit and ignition coil
Disconnect coils and the side connec-
tor of the ignition coil of the ignition unit.
- Terminals N07, N54, N65 and N84 on the cable
harness side of each ignition coil D
- Terminals C1, C2, C3 and C4 on the cable har-
ness side of the ignition unit C. Repair or replace
the cable harness or the connector.
Electronic Control Unit of the Fuel Injection
and the ignition unit.
Disconnect the connector of the spe-
cial tool from the Electronic Control
Unit of the Fuel Injection.
Disconnect the ignition unit connector
on the Electronic Control Unit side E.
- Terminals S1, S2, S3, S4 on the cable harness
side and Input/Output of the ignition unit.
- special tool connector terminals 60, 59, 58, 57
and 14, repair or replace the cable harness or the
connector, otherwise go back to step 7.
IS - 514
P1510 - Malfunzionamento circuito segnale avviamento
Checking procedure
The diagnosis diagram is based on the assump-
tion that the engine is started under normal condi-
tions.
1. Checking the input signal of the STA Elec-
tronic Control Unit
ness).
Measure voltage between connectors
68 and 82 STA-E01 of the special tool
with the following conditions.
Condition Specified value
Engine started with starter motor 6 - 10 V
After the engine start-up: 0V
If the value measured matches the specified value,
check the malfunction that is detected intermittent-
ly and bad contacts, otherwise proceed with step
2.
2. Checking the cable harnesses between the
ignition switch and the Electronic Control Unit
(M/T vehicles)
Disconnect the ignition switch connec-
tor.
cial tool on the Electronic Control Unit
side.
M/T vehicles: Connector N30 on the
ignition switch side - connector 68 STA
on the Electronic Control Unit side. Re-
pair or replace the cable harness or the
connector, if necessary, otherwise
check or replace the Engine Electronic
Control Unit side.
IS - 515
KEY:
1. Ignition switch
2. 60A fuse F/L
3. Battery
4. Starter motor
Circuit description
When the engine is started with the starter motor, the intake air flow is slow, that is why there is a lean
combustion vaporisation. A rich mixture is therefore necessary in order to obtain a proper start-up. When
the engine is started with the starter motor, the battery positive voltage is applied to the terminal STA
of the Engine Electronic Control Unit. The start-up signal is used mainly to increase the fuel injection
volume for the start-up injection and post-start-up injection check.
Conditions
Affected area
P1510 Interrupted or short-circuited wire in the start-
up signal circuit.
- Interrupted or short-circuited wire in the start-
up signal circuit.
THE CODE P1510 CAN BE DETECTED AFTER START-UPS WITHOUT USING THE STARTER
MOTOR.
IS - 516
P1520 - Malfunzionamento circuito segnale interruttore
Using the diagnostic tester DS-21
1. Checking the input signal through the C/A switch of the idle switch to the Electronic Control
Unit
Set the ignition switch to OFF. Connect the diagnostic tester DS-21 to the Data Link Con-
nector through the special tool.
Specific tooling
Set the ignition switch and the tester main switch to ON. Check the idle switch signals (To
perform this operation, refer to the user manual of the diagnostic tester DS-21.
If failures are detected during checks, inspect the
malfunction that is detected intermittently or due to
false contact.
2. Check the cable harnesses between the
throttle valve sensor and the Electronic Con-
trol Unit
Model EURO 3
ness). Do not connect the connector of
the special tool to the Electronic Con-
trol Unit.
ness and connector.
Connector XT1 on the sensor side - connector on
the 17 E2 electronic control unit side.
Connector XT0 on the sensor side - connector on
the 44 VTH electronic control unit side.
IS - 517
Connector X99 - on the sensor side - Connector
on the 16 VC electronic control unit side.
Model EURO 4
connect the special tool to the cable
harness connectors coming from the
DRACO control unit on the EFI ECU
side.
Check the cable harness downstream
and upstream the DRACO control unit
and on the DRACO itself:
Connector XT1 on the sensor side - DRACO con-
nector B4
DRACO connector 3/21 - EFI ECU connector 17
E2.
Connector XT1 on the sensor side - DRACO con-
nector B4
VTH.
Connector X99 - on the sensor side - DRACO con-
nector B3
VC.
Repair or replace the cable harness, if necessary,
otherwise check the throttle valve sensor and re-
place it, if necessary.
Alternatively, check or replace the EFI ECU control
unit.
IS - 518
KEY:
1. Ignition switch
2. Throttle valve sensor wire on the cable harness side
4. 60A fuse F/L
5. Battery
Model EURO 4
IS - 519
KEY:
1. Ignition switch
2. Throttle valve sensor wire on the cable harness side
4. 60A fuse F/L
5. Battery
7. Draco
Circuit description
This code is used to check the throttle valve signal. With terminal T set to ON, the diagnostic code failure
is generated for cases in which the throttle valve sensor is set differently from idle. However, the failure
code is diagnosed only if terminal T is set to ON. It is not stored.
Conditions
Affected area
P1520 When conditions 1 and 2 described below are
fulfilled:
1. terminal T set to "ON"
2. Idle switch set to "OFF", air conditioner set
to "ON" or neutral starter switch set to "ON"
- Interrupted or short-circuited wire in the throt-
tle valve sensor circuit
- Engine Electronic Control Unit
IS - 520
IF THE IDLE SWITCH TURNS OFF WHILE TERMINAL T IS SET TO ON, IT IS POSSIBLE TO IN-
SPECT, IF THE IDL SYSTEM OF THE THROTTLE VALVE SENSOR WORKS PROPERLY BY
CHECKING THE DIAGNOSTIC FAILURE CODE GENERATED.
Checking procedure
If the diagnostic failure codes P0110, (intake air temperature circuit malfunction), P0115 (engine coolant
temperature circuit malfunction), and P0120 (Throttle/pedal position sensor switch malfunction A) are
generated at the same time, the Sensor Ground E2 could be open.
1. Check the input signal of the electronic control unit
With the ignition switch to ON, measure the voltage between connectors 16 , 17 VC and E2,
44 , 17 VTH and E2.
Characteristic
specified value:
16 , 17 VC and E2: 4.5 - 5.5 V .
44 , 17 VTH and E2: move the throttle lever from the completely closed to the completely open position,
voltage must increase proportionally from 0 to 4.8 V.
false contact, otherwise proceed with step 2.
2.Checking the cable harness between the neutral starter switch and the electronic control unit.
As for switch C/A and the throttle valve sensor, go to step 2 of the section: Using the diagnostic tester
DS - 21 Repair or replace the cable harness or the connector, if necessary, otherwise check or replace
the engine electronic control unit.
IS - 521
P1560 - Malfunzionamento circuito alimentazione ausiliaria unit di
controllo elettronica
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Main relay
11. Fuel pump relay
Circuit description
Battery positive voltage is delivered to the BAT terminal of the engine electronic control unit also when
the ignition switch is turned off to keep failures and self-adaptive parameters relative to the air-fuel ratio
check, etc. stored.
IS - 522
Conditions
Affected area
P1560 Interrupted wire in the auxiliary power supply
circuit
- Interrupted wire in the auxiliary power supply
circuit
IF THE CODE P1560 IS DISPLAYED , THE ELECTRONIC CONTROL UNIT DOES NOT STORE
ANOTHER CODE.
Checking procedure
1. Checking the auxiliary power supply voltage of the electronic control unit
With the ignition switch to OFF, measure voltage between the 1 BAT connector and the
chassis ground.
Characteristic
specified value:
battery voltage
Check the malfunction that is detected intermit-
tently or due to false contact, if necessary.
2. Check the cable harness between the relay
block and the electronic control unit
With the ignition switch set to OFF, dis-
connect the special tool connector
from the control unit.
Remove the cable harness from the
battery terminal. Check there are no
interrupted or short-circuited wires in
the cable harness and connector.
IS - 523
Cable harness side connector L41 of R/B - elec-
tronic control unit 1 BAT.
Cable harness side connector L41 of R/B battery
(+) terminal, repair or replace the cable harness or
connector.
3. Checking the electronic fuel injection fuse
No.1
Remove fuse No.1 from the bulb hold-
er.
Check continuity of fuse No.1. If it is in
proper conditions, check or replace the
engine electronic control unit.
P1667 - Malfunzionamento circuito valvola controllo sistema ricircolo gas
di scarico
Using the tester DS-21
1. Functional check of the EGR vacuum switch-
ing valve control system
special tool.
Specific tooling
Disconnect the suction pipe that goes
from the EGR vacuum modulator to the
vacuum switching valve and to the vac-
uum switching valve pipe.
Set the ignition switch and the tester
main switch to ON. Clear the diagnos-
tic failure code. Select the "VSV 1 driv-
ing" from the "Actuator control".
When switching ON and OFF, check
the operation of the "VSV 1 driving".
IS - 524
- Valve set to OFF: there must be no air continuity
when air is blown into the suction pipe with pipe
A closed. Afterwards, there must be air continuity
when air is blown into the suction pipe with pipe
A open.
- Valve set to ON: there must be air continuity
when air is blown into the suction pipe, and there
must be no air continuity inside the suction pipe.
- If failures are detected during checks, inspect the
false contact, otherwise proceed with step 2.
KEY:
1. EGR vacuum modulator
2. EGR valve
2. Checking the suction pipes
"Release" the vacuum switching valve
so as to set the vacuum switching valve
for EGR to the original operating mode.
Start the engine and let it run.
Disconnect the suction pipe that goes
from the vacuum switching valve for
EGR to the throttle body.
Cover the pipe with a finger. Check that
a negative pressure is applied. Speci-
fications: a negative pressure must be
applied.
Check there are no leaks, rust, narrow-
ing, bending and deformations on the
suction pipe connection. Clean, repair
or replace, if necessary.
KEY:
3. Switching valve
4. Throttle body
5. Suction pipe
3. Checking the power supply voltage of the vacuum switching valve for EGR.
Set the tester main switch and the ignition switch to OFF.
Disconnect the vacuum switching valve connector.
IS - 525
With the ignition switch set to ON, measure voltage between the cable harness side con-
nector XF of the valve and the body ground.
Characteristic
specified value:
battery voltage.
uum switching valve for EGR and the main relay,
and that there are no interrupted or short-circuited
wires in battery. Repair or replace, if necessary.
valve for EGR
tor of the special tool to the electronic
control unit.
ness and connector. Connector XAE
on the valve cable harness side - con-
nector 80 on the VSV1 electronic con-
trol unit side. Repair and replace the
cable harness or the connector, if nec-
essary.
5. Checking the vacuum switching valve for EGR
Replace the vacuum switching valve for EGR, if necessary.
6. Checking the output signal of the electronic control unit
Connect the connector to the vacuum switching valve for EGR. Connect the connector of
the special tool to the electronic control unit of the electronic fuel injection. Reconnect the
pipes previously removed in the original position.
With the engine cold and the vehicle running, measure voltage between connectors 80 and
82 of the special tool VSV1-E01.
IS - 526
Characteristic
specified value:
battery voltage.
After warming up the engine (after the cooling fan has started at least once), measure volt-
age between connectors 80 and 82 VSV1 - E01 with the vehicle running at a speed of 60
km/h (4a gear) - max. 4800 rpm.
Characteristic
specified value:
the voltage must shift from 0 to 1 V.
false contact, otherwise check or replace the elec-
KEY:
1. Ignition switch
2. 60A fuse F/L
IS - 527
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
9. Cable harness side wire
10. Vacuum switching valve (VSV) for ERG
11. Injector
Circuit description
In order to reduce NOx emissions, the anti-pollu-
tion system with exhaust gas recirculation (EGR)
allows the recirculation of an ideal quantity of ex-
haust fumes inside the inlet manifold according to
riding conditions, moderating combustion. The
suction pipe leading to the EGR valve is equipped
with a vacuum switching valve. Therefore, if EGR
working conditions are fulfilled, the electronic con-
trol unit closes the atmospheric inlet opening of the
vacuum switching valve allowing the conduction of
vacuum to the EGR valve. In this way, the recir-
culation of exhaust fumes is obtained.
KEY:
1. Vacuum modulator
2. ECU
3. Switching valve
4. EGR valve
5. Throttle body
Conditions
Affected area
P1667 If there are interrupted or short-circuited wires
in the vacuum switching valve for EGR and
conditions necessary to carry out the recircu-
lation of exhaust fumes have been fulfilled:
- Interrupted or short-circuited wire in the circuit
of the vacuum switching valve for EGR
- Vacuum switching valve for EGR
Checking procedure
NOTE:
IS - 528
Circuito alimentazione unit di controllo elettronica
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Main relay
11. F/P Relay
Model EURO 4
IS - 529
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Main relay
11. F/P Relay
13. Draco
Circuit description
With the ignition switch set to ON, apply battery positive voltage to the coil, closing the contacts of the
electronic fuel injection main relay and powering terminals +B1 and +B2 of the engine electronic control
unit.
Checking procedure
IS - 530
1. Checking the electronic control unit power supply voltage
With ignition switch set to ON, measure voltage between connectors 7, 36 up to 82 E01.
Characteristic
specified value:
battery voltage.
If it matches the specified value, check the mal-
function that is detected intermittently or due to
false contact (see the relevant section).
2.Checking the cable harness between the re-
lay block and the electronic control unit.
connect the special tool connector
from the electronic control unit.
battery positive +terminal.
ness and connector (For the model
EURO 4, the circuits in question com-
prise the cable harnesses downstream
and upstream the DRACO control unit
and on the DRACO itself).
Connector L33 of the relay block on the cable har-
ness side and terminal 7 and 36 of the special tool.
Connector L41 of the relay block and battery pos-
itive (+) terminal.
IS - 531
3. Checking the main relay of the electronic
fuel injection
Disconnect the main relay of electronic
fuel injection from the relay block.
Check for proper operation and re-
place the main relay of the electronic
fuel injection, if necessary.
KEY:
1. Fuel pump relay
2. Main relay
4. Ignition switch check
Disconnect the connector from the ignition switch.
With the ignition switch disconnected, check continuity between the terminals shown below.
Switch position Continuity terminal No.
LOCK -
IGN 4 - 5
ON 2 - 3 - 4 - 5
START 1 - 2 - 3 - 4
If checks do not correspond, replace the ignition
switch.
5. Check that there are no interrupted or short-
circuited wires in the cable harness and the
connector among the ignition switch, relay
block and chassis ground
KEY:
4. R/B wire on the cable harness side
IS - 532
6. Checking the electronic fuel injection fuse
No.2
Disconnect the electronic fuel injection
fuse No.2 from the fuse board.
Check if there is continuity in fuse No.
2.
Replace the fuse, if necessary, otherwise check
and replace the electronic control unit.
Circuito controllo pompa carburante
IGNITION SWITCH
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Main relay
IS - 533
11. Fuel pump relay
12. Data Link Connector (DTC )
Checking procedure
1. Functional check of the fuel pump
special tool.
After setting the ignition switch to ON,
set the tester main switch to ON. Select
the actuator control.
With your fingers, press down the fuel
pipe on the main pipeline.
Activate the fuel pump. If there is no
diagnostic tester DS-21 available, con-
nect a linking wire between terminal T
of the Data Link Connector and the
ground terminal.
If there is no pressure increase, check the mal-
function that is detected intermittently or due to
false contact.
2. Checking the power supply circuit of the en-
gine control unit. Check according to failures
identified in the power supply circuit of the
electronic control unit
Repair or replace, if necessary.
3. Checking the fuel pump relay
connect the fuel pump relay A from the
relay block.
Check the relay and replace it, if nec-
essary.
4. Voltage check on terminal FC2 of the engine electronic control unit
Set the ignition switch to ON.
IS - 534
Measure voltage between the connector 30 W/0 IMB of the special tool and the chassis
ground.
Characteristic
specified value:
battery voltage.
If it does not match the specified value, check
there are no interrupted or short-circuited wires in
the cable harness and the connector between the
relay block and the electronic control unit.
5. Fuel pump check
Repair or replace the fuel pump, if necessary.
6. Checking the cable harness between the relay block and the fuel pump
Check there are no interrupted or short-circuited wires in the cable harness and the connector.
- Relay block - fuel pump.
- Fuel pump - chassis ground.
Repair or replace the cable harness or the connector, if necessary, otherwise check or replace the
electronic control unit.
IS - 535
Malfunzionamento sistema valvola di commutazione VSV
KEY:
1. Ignition switch
2. 60A fuse F/L
5. Main relay
6. Fuel pump relay
7. Battery
8. Fuel pump
10. Cable harness side wire
11. To the cooling fan
12. To the front headlight switch
13. To the heater fan switch
14. To the anti-fog system switch
15. Vacuum switching valve to increase idle speed
IS - 536
Circuit description
The solenoid valve to increase idle speed is loca-
ted on the compensation chamber of the inlet
manifold. The intake air by-passes the throttle
valve through the vacuum switching valve.
In this way, the engine electronic control unit in-
creases idle speed controlling the vacuum switch-
ing valve.
KEY:
1. Throttle body
2. Vacuum switching valve to increase idle speed
Conditions
Affected area
- Interrupted or short-circuited wire in the ISC
valve circuit.
- Interrupted or short-circuited wire in the circuit
of the vacuum switching valve
- Vacuum switching valve
Checking procedure
1. Functional check of the vacuum switching valve to increase idle speed
Connector through the special tool.
Specific tooling
Warm up the engine with all the acces-
sory switches set to OFF.
Set the main switch of the diagnostic
tester DS-21 to ON.
With the engine running at idle speed,
select the VSV2 from the Actuator con-
trol. Set the VSV2 to ON.
If there is an increase of engine speed, check the
false contact.
2. Checking the power supply voltage of the vacuum switching valve.
Set the tester main switch and the ignition switch to OFF.
IS - 537
Disconnect the connector of vacuum switching valve to increase idle speed.
Measure voltage between terminals XAC of the cable harness connector and the body
ground with the ignition switch set to ON.
Characteristic
specified value:
battery voltage.
uum switching valve and the main relay, and that
there are no interrupted or short-circuited wires in
battery.
3. Checking the output signal of the electronic
control unit vacuum switching valve terminal
After warming up the engine and after
stopping it, set the ignition switch and
the main switch of the diagnostic tester
DS-21 to ON.
Select VSV2 ON from the Actuator
control. Measure voltage between ter-
minals 56 and 82 E01.
Characteristic
Specified value
0-0.5 V
Check and replace the electronic control unit, if
necessary.
vacuum switching valve and the electronic
control unit
cial tool on the Electronic Control Unit
side.
IS - 538
ness and connector.
Vacuum switching valve connector XAB - terminal
56 VSV2. Repair and replace the cable harness or
5. Checking the vacuum switching valve to increase idle speed
Replace the vacuum switching valve to increase idle speed, if necessary.
6. Checking the input signal of the electronic control unit to verify the electric charge
With the engine running, measure voltage between terminals 56 and 82 VSV2 - and E2,
E01.
- Condition Specified value
1 Until the complete engine warm-up, after start-up with cold en-
gine
0.5 V or less
2 Anti-fog system switch set to ON 0.5 V or less
3 Heater fan switch set to ON 0.5 V or less
4 Front headlight switch set to ON 0.5 V or less
5 Cooling fan activated 0.5 V or less
N.B.
DO NOT PERFORM THE MEASUREMENT IF MANY CONDITIONS TAKE PLACE AT THE SAME
TIME.
If it does not match the specified value, check and
repair the relative systems, otherwise check the
malfunction that is detected intermittently and bad
contacts.
Controlli generali
(IAT) Intake air temperature sensor
1. Measure resistance between terminals.
IS - 539
Referen
ce
values
Temper-
ature (
C)
-30 -20 20 80 120
Resist-
ance
(kOhm)
28.6 16.2 2.45 0.33 0.18
(CANISTER VSV) Vacuum switchover valve for
bleeding fuel evaporative emissions.
Check continuity between the outlets.
Specifications: there must not be continuity.
2. Apply voltage to the connector terminals of the
CANISTER VSVvalve and check continuity be-
tween openings.
Specifications: there must be continuity.
3. Measure the resistance value between termi-
nals.
Characteristic
specified value:
Spark plug
The spark plug could be too hot. Watch out not to get burned.
1. Check that the spark plug is not dirty or too hot.
2. Check the gap between spark plug electrodes using the proper tool.
Characteristic
Electrode gap = 0.9 / 1.0 mm
3. Check the value of the spark plug internal re-
sistance.
Characteristic
Specified value:
3.0 - 7.5 Ohm
IS - 540
(TPS) Throttle valve sensor
1. Measure resistance between VC and E2.
2. Measure the resistance variation between VTH
and E2.
Specification: the resistance value should in-
crease according to the gas lever degree of open-
ing.
KEY:
A:Throttle valve sensor (PTS)
Characteristic
Specified value
2.5 - 5.0 Ohm
With the throttle lever fully open the resistance
value must be around
3.4 kOhm
With the throttle lever fully closed the resist-
ance value must be around
0.4 kOhm
(VSV2 MIN) Vacuum switchover valve for in-
creasing idle speed.
1. Check continuity between outlets.
Specifications Value: there must not be continu-
ity.
2. Apply voltage to the connector terminals of the
vacuum switchover valve and check continuity be-
tween openings.
Specifications Value:there must be continuity.
3. Measure the resistance value between the ter-
minals.
Characteristic
Specified value
37 - 44 Ohm at 20C
IS - 541
(ECT) Engine coolant temperature sensor
1. Measure resistance between terminals.
Circuit diagram - Key
1. Thermistor for electronic fuel injection
2. Thermistor for water temperature gauge
KEY:
T: Temperature
R: Resistance
VSV EGR - Vacuum switchover valve for EGR
1. Check the continuity between openings. Spec-
ifications: there must be continuity between open-
ings G and E. There must not be continuity
between openings E and F.
2.Apply voltage to the connector terminals of the
vacuum switchover valve and check continuity be-
tween the openings. Specifications: there must be
continuity between openings E and F. There must
not be continuity between openings G andE.
3.Measure the resistance value between the ter-
minals.
Characteristic
Specified value:
30 - 34 Ohm at 20C
IS - 542
Fuel pump
1. Turn the ignition switch to ON.
2. Short circuit terminals T and E of the Connecting
Connector in Data Transmission using the specific
tool. Check if the relay emits a sound signal indi-
cating it is operating.
3.Turn the ignition switch to OFF.
4. Remove the connector placed on the fuel tank.
Measure resistance between the fuel pump termi-
nals
- IT IS STRICTLY FORBIDDEN TO USE NAKED FLAMES
WHILE PERFORMING THIS PROCEDURE.
Specific tooling
Characteristic
Specified value
from 0.2 to 3.0 Ohm
Main relay and fuel pump relay
1. Turn the ignition switch to ON. Check that the
relay is working paying attention to the sound sig-
nal and vibration.
- CHECK THAT THE RELAY IS VERY HOT DURING THIS
OPERATION. DO NOT TOUCH IT WITH BARE HANDS.
2. Measure resistance between terminals 1 and
2.
3. Check that there is no continuity, except be-
tween terminals 1 and 2.
4. Apply battery voltage between terminals 1 and
2. Check that there is continuity between terminals
3 and 4.
- MEASURE AFTER THE RELAY HAS BEEN SLOWLY
LOADING FOR AT LEAST ONE HOUR AT AMBIENT TEM-
PERATURE OF 0C-40C.
Characteristic
Specified value
IS - 543
from 74 to 117 Ohm
Front and rear oxygen sensors with heater
(For EU specifications only)
1. Measure resistance between terminals (+B) and (HT).
Characteristic
Specified value:
from 11.7 to 14.5 Ohm at 20C
Ignition unit (For EU specifications only)
1- Measure resistance between the following con-
nector terminals.
TERMINAL RESISTANCE VALUES
I/O G1 1.9 - 2.1 k
S1 G2 3.7 - 4.1 k
S2 G2 3.7 - 4.1 k
S3 G2 3.7 - 4.1 k
S4 G2 3.7 - 4.1 k
IS - 544
INDEX OF TOPICS
GEAR-BOX GE
Gearbox
This section of the manual describes the gear components and shows the removal/fitting operations.
Precautions
Before removing and fitting a new gear, it is necessary to observe the following precautions:
It is advisable to use the following special tools, so that parts are not damaged.
The gear removal procedure has been omitted, since the procedure above is the same
applied to the gears used so far.
It is advisable to carry out removal operations after the checks (as for example: the proper
operation of the gear and excessive clearance, etc.) that can be only lead when the gear is
assembled.
It is advisable to check the tightening torque when it is detected that the main section bolts
are loosened.
From checking confirmations, it is possible to discover which can be the cause of the problem
which has rendered the removal necessary (for example: oil leakage, abnormal noise, etc.).
As regards those sections which require measurements and accurate surveys, which may
be conducted more easily when the assembly is fitted (as for example: the gear fork as-
sembly and hub, the thrust clearance of each gear, etc.:), it is advisable to conduct those
measurements also during removal.
FOR REMOVING AND FITTING THE CONICAL SPRING WASHER
Total width 75.00 mm
Total width 70.00 mm
Total inside width 65.00 mm
Height 40.00 mm
Thickness 5.00 mm
The figure shows positions related to the special
tool Drw. 020277Y - bracket.
Gear-box PORTER 1.3 16V
GE - 546
Tool to be used from the input shaft and the sec-
ondary shaft side.
D. 80.00
d. 36.00
F. 15.00
L. 200.00
R. 185.00
A. 42.00
The figure shows positions related to the special
tool Drw. 020202y.
Tool to be used from the input shaft and the sec-
ondary shaft side for the synchroniser.
t. 8.00
L. 250.00
W. 75.00
P and D. Make sure that the outside diameter
D is 55 mm with a 10 mm thickness interposed
matching section P.
P is used as a guide, when the
grooved pin of the gear control fork
spring is inserted in its seat.
D =4.00 mm L =50.00 mm.
Y is used when it is checked by man-
ually turning the main shaft that the
transmission assembly works properly.
The part Y is inserted in the fork from the pro-
peller shaft front end, when the main shaft is
turned.
Diagram
1. The manual gear has five speeds for all the models.
2. The layout of the gear train is changed from the conventional method with primary reduction to that
of output reduction.
3. The mechanism to avoid noise and excessive clearance has been changed from the conventional
method by damped friction to that which uses the sub-gear.
PORTER 1.3 16V Gear-box
GE - 547
A =Gear section
B =Pin and fork section
Gearbox and cover
1. In order to reduce the number of gearbox com-
ponents, the gear system has been altered. At the
same time, in order to decrease the possibility of
oil leaks, the possible oil leak sections have been
reduced.
2. In order to improve rigidity, the gear transverse
section has been changed, from the conventional
"U" to the cylindric shape.
3. To reduce weight, each housing has been made
in aluminium die-casting.
In addition, there are special ribs on each housing
which allow to obtain a compact design and a
weight reduction.
KEY
1. Clutch bell
2. Gearbox
GE - 548
3. Selection pin cover
4. Rear cover
Sub-gear
1. Each single sub-gear has one tooth less with
respect to the main gear; in this way, a phase
movement towards the main gear can be obtained.
This makes possible to remove clearance among
the teeth at the moment of meshing with the main
gear. In addition to this, an elastic spring (conical)
placed between the sub-gear and the main gear
avoids any noise when shifting gears.
2. The sub-gear is fitted in secondary shaft speed
I and II
KEY
1.Sub-gear
2. Main gear
3. Main gear
4. Conical spring washer
5. Retaining circlip
6. Sub-gear
Components
Cambio (parte 1)
COMPONENTS
1. Clutch housing
GE - 549
2. S type oil seal
3. Gear synchronisation plate
4. Spring
5.Reverse gear control lever
6. Plate locking the input shaft bearing
7. Reverse transmission gear
8. Reverse transmission gear thrust washer
9. Reverse transmission gear shaft
10. Pin
11. Hexagonal bolt
12. Gasket
13. Gasket
14. Spring
15. Ball
16. Control fork shaft of the 5th gear and the reverse gear
17. Control head of the 5th gear and the reverse gear
18. Pin
19. Control fork of the 5th gear
20. Control fork shaft of the 3rd and 4th gear
21. Control head of the 3rd and 4th gear
22. Control fork of the 3rd and 4th gear
23. Control fork shaft of the 1st and 2nd gear
24. Control fork of the 1st and 2nd gear
25. Control head of the 1st and 2nd gear
26. Oil reception duct
27. Cap with gasket
28. Gearbox
29. Oil drainage plug (magnetised)
* Non-reusable parts
1. Clutch housing
The clutch body is connected to the gearbox by means eight bolts M8 (I =40 mm) and two bolts M8 (I
=60 mm).
Clutch cover 1522
*2. " S" type oil seal
Lubricate the gasket lip with engine oil during fitting. Press slightly on this gasket by means of a 35 mm
pipe.
3. Gear synchronisation plate
GE - 550
Total length =23.25 - 23.55 mm
Internal part length =17.7 -17.9 mm
A similar plate is used in other two points.
4. Spring
The tension spring is fitted between parts 5 and 6 of this list.
5. Reverse gear control lever
Make sure that the operation pin moves slightly and freely between the neutral position and the 5th
gear. The control lever of the reverse gear is fitted with three bolts M8 (I =20 mm)
6. Bearing locking plate
The bearing locking plate of the input shaft is fitted with three bolts M8 (l =20 mm)
7. Reverse transmission gear
Bushing hole diameter D =20.03 - 20.06 mm. Pay attention to fit it in the proper direction.
8. Reverse transmission gear thrust washer
Nylon washer.
9. Reverse transmission gear shaft
D =20 mm This shaft is locked by means of the hexagonal bolt 11.
*10. Pin
Make sure that the part that comes out from the shaft is of 2.5 mm or less.
11. Hexagonal bolt
Black bolt, hexagonal head. Extract this bolt only when the gear is removed.
*12. Gasket
*13. Gasket
Control fork shaft 15 - 22 Nm
14. Spring
A similar spring is used in other three different points L =40 mm . This compression spring is locked
by means of a bolt M10 (I =19 mm).
Gear control fork shaft screw - Clutch housing 1930
15. Ball
A similar spring is used in other three different points, including the reverse gear limit ball.
D =7.9375 mm
16. Control fork shaft of the 5th gear and the reverse gear
This control fork shaft is the longest among the three shafts.
L =265 mm
GE - 551
D =13.0 mm
17. Control head of the 5th gear and the reverse gear
Width of the area making contact with the internal lever: 12.1 -12.2 mm
Width of the area making contact with the reverse gear control arm pin: 15.0-15.043 mm
*18. Pin
A similar pin is used in other six different places.
D =5 mm
L =23 mm
19. Control fork of the 5th gear
Thickness of the section of the fin making contact with the hub bushing:
D =6.7 - 6.9 mm
20. Control fork shaft of the 3rd and 4th gear
This shaft has an intermediate length with respect to the three shafts.
L =259 mm
D =13.0 mm
21. Control head of the 3rd and 4th gear
Groove depth corresponding to the section making contact with the internal control: 12.1 12.2 mm
22. Control fork of the 3rd and 4th gear
Thickness of the section of the fin making contact with the hub bushing: 6.7 - 6.9 mm
23. Control fork shaft of the 1st and 2nd gear
This shaft is the shortest among the three shafts.
L =224 mm
D =13.0 mm
24. Control fork of the 1st and 2nd gear
Thickness of the section of the fin making contact with the hub bushing: 9.7 - 9.9 mm (This fork is longer
than the others).
25. Control head of the 1st and 2nd gear
Groove depth corresponding to the section making contact with the internal control: 12.1 - 12.2 mm
26. Oil reception duct
The duct is located inside the gearbox and it is fixed by means of a bolt M6 (I =16 mm).
27. Cap with gasket
Remove this cap, only in case of an oil leak (or similar event)
28. Gearbox
The clutch body is linked to the gearbox with 10 bolts.
Clutch housing for gearbox 15 - 22 Nm Engine fitting rear bracket for gearbox cover 29 44 Nm
29. Oil drainage plug (magnetised)
GE - 552
This magnet is not locked with any bolt.
Cambio componenti
COMPONENTS
34. Spring
35. Reverse gear limit cam
36. Reverse gear limit shaft
37. Subassembly of the selection lever
38. Pin
39. Gear control shaft cover
40. Gasket
41. Spring
42. Selection internal lever
43. Main shaft
44. Reverse gear limit pin holder
45. Gasket
46. Spring
47. Ball
48. Gearbox
49. Gear internal lever
50. Gear control shaft subassembly sleeve
51. Pin
52. Gear control shaft subassembly
53. Radial bearing
54. Circlip
GE - 553
55. Lock nut
56. Odometer control gear
57. Radial bearing (rear)
58. Bearing rear locking
59. Oil seal
60. Gasket
61. Filler cap
62. Bimetallic bushing
63. T oil seal
64. Dust guard
65. Housing subassembly
66. Plate locking the odometer sleeve
67. V oil seal
68. Gasket
69. Sleeve assembly of the rpm indicator shaft
70. Gasket
71. Rpm indicator guide gear subassembly
72. T oil seal
73. K Oil seal
74. Oil guide plate
34. Spring
Pay special attention to the fitting direction, which shall be the same to the 35 part.
35. Reverse gear limit cam
Pay special attention to the fitting direction (during the removal and fitting phases), so that the reverse
gear limit cam has the proper fitting direction.
36. Reverse gear limit shaft
D =8 mm, L =7.15 mm.
37. Subassembly of the selection lever
Pay special attention to the lever fitting direction when the components are fitted 41 and 42.
*38. Pin
D =6 mm, L =22 mm
Fit this pin in its seat, inserting it from the side without the groove.
39. Gear control shaft cover
The gearbox cover is fitted with four bolts; three bolts M8 (L=28 mm) and the remaining bolt (olive-
green) always M8 (L=19 mm). Component 40 is interposed between the cover and the gearbox.
*40. Gasket
(No asbestos).
GE - 554
41. Spring
Pay attention to the fitting direction (upside down) of the spring, during fitting.
42. Selection internal lever
Width of the section making contact with the control head: 4.88-14.98 mm
43. Main shaft
This shaft corresponds to the 4th gear.
44. Reverse gear limit pin holder
*45. Gasket
Unloaded length: 24.00 mm
46. Spring
Fitted length: 17.00 mm
47. Ball
A similar ball is used in four different positions, including the gear control fork ball.
48. Gearbox
Refer to "Components (Part 1 )" for the description. Apply liquid sealant onto sections coupling with the
clutch housing and the housing rebound.
49. Gear internal lever
Width of the section making contact with the control head: 11.88 11.98 mm
50. Gear control shaft subassembly sleeve
Width of the section making contact with the selection internal lever: 15.1 15.2 mm
Fit this sleeve so that the air bleeding section is facing downwards.
*51. Pin
D =6 mm, L =24 mm
52. Gear control shaft subassembly
Pay special attention to the lever fitting direction.
53. Radial bearing
Press on the bearing from the side having the gasket facing backwards.
54. Circlip
This circlip can be reused.
*55. Lock nut
Lock nut thickness: 38 mm
Tightening torque: 177 - 216 Nm
56. Odometer control gear
Make sure to fit the lock nut after the tightening operation. Made of nylon.
GE - 555
Pay attention not to deform the gear due to an excessive pressure during fitting. For the fitting procedure,
make reference to the next part 57.
57. Radial bearing
Insert this bearing by pressure, keeping the gasket side facing backwards. Also, pay attention when
pressing the bearing. Carry out the measurement at the moment in which the bearing comes slightly
into contact with the rpm indicator gear. At this point, check that the value measured from the edge of
the main shaft is 93.0 mm.
58. Bearing rear locking
This locking device is fitted with three bolts M8 (I =20 mm)
Tightening torque 14.7 - 21.6 Nm
59. Oil seal
Made of nylon. (This deflector is also called oil deflector of the 5th gear).
*60. Gasket
61. Filler cap
The cap located at the top, is used either to add oil or to check oil level. (The capacity is of 1.0 1.1
litres when oil is added before it starts to circulate). The cap located at the bottom is used to drain oil.
Tightening torque: 29.4 49.0 Nm
62. Bimetallic bushing
In cases in which only the bushing is replaced, pay attention that the contact section has 120 distance
with respect to the oil groove.
*63. T oil seal
The gasket inclination, at the time of positioning it in the seat by pressure, shall be of 1 or less. Apply
MP grease onto the lip section.
64. Dust guard
Pay attention to the handling of this deflector, because it can be easily deformed.
65. Housing subassembly
This component is treated as a subassembly on which components 62 and 64 are fitted. The gearbox
cover is fixed with six bolts M10 (I =35 mm).
From these six bolts, one is locked together with the engine support bracket.
Tightening torque29.4 - 49.0 Nm
66. Plate locking the odometer sleeve
Fit this locking plate with a bolt M6 (I =16 mm). Tightening torque: 6.9 9.8 Nm.
67 V oil seal
68 Gasket
Before replacing this part with a new one, measure beforehand the insertion depth of part 69. Then,
insert the new part by pressure up to the same depth.
69. Sleeve assembly of the rpm indicator shaft
GE - 556
Fit this assembly with part 66 interposed. Components 67 to 71 are generally used as a set.
70. Gasket
71. Rpm indicator guide gear subassembly
Fit this gasket in the external groove of part 69. Made of nylon.
Gear oil
Filling capacity: 1.0 1.1 litres
Place the vehicle on level ground and fill with oil up to the lower edge of cap 61. SAE 75W-90 or 80W-
go API GL-3.
72. T oil seal
During the fitting phase, strictly observe the protrusion size, which shall be of 5 0.3 mm.
73. K Oil seal
The gasket inclination, at the time of positioning it in the seat by pressure, shall be of 1 or less. Apply
MP grease onto the lip section.
74. Oil guide plate
This plate is fitted inside the gearbox.
Tightening torque: 6.9 - 9.8 Nm
Repairs to be carried out on the vehicle
1. Sleeve assembly of the rpm indicator gear.
2. Box gasket and cover.
3. Oil deflection and bearing locking.
4. Control gear of the rpm indicator, radial bearing and the oil drainage screw.
5. Check that there is continuity between the reverse gear light switch and engagement of the reverse
gear.
Removal
Recommendations before removal
This section has a summary of the gear main components illustrated in the sections:
Component Gear (Part 1)
Component Gear (Part 2)
Input shaft
Secondary shaft
The description facilitates the removal and fitting operations. For clearer and further details, refer to the
corresponding pages.
GE - 557
Removal
Removing the parts connected to the gear and
to the selection lever
1. Remove the clutch components.
2. Place the gearbox assembly and the clutch
housing in a vertical position so that the gearbox
is under the clutch.
- AFTER CHECKING THE CONTINUITY OF THE REVERSE
GEAR LIGHT SWITCH:
3. Remove the control shaft cover with the gasket
(bolt C is used as a centring bolt).
4. Remove the compression spring and the ball
locking the reverse gear limit pin with the gasket.
5. Remove the compression spring and the ball by
taking out the reverse gear limit pin locking B with
the gasket.
6. Remove the hexagonal bolt A from the reverse
transmission gear with the gasket.
- REMOVE THE COVER OF THE GEAR CONTROL SHAFT,
AS REQUIRED.
- BEFORE REMOVAL, TAKE OUT THE GROOVED PIN
FROM THE GEARSHIFT LEVER SHAFT.
- THIS HEXAGONAL BOLT IS USEFUL TO LOCK THE RE-
VERSE TRANSMISSION GEAR. THEREFORE, TAKE OUT
THIS BOLT BEFORE THE GEAR IS REMOVED.
7. Take out the gearshift lever subassembly and
lift the internal lever, after removing the grooved
pin.
8. Remove the reverse gear limit cam A, the tor-
sion spring B and the reverse gear limit shaft C,
taking out the hexagonal bolt with the gasket.
9. Remove the reverse gear light switch with the
gasket.
- DURING THE ASSEMBLY, OBSERVE THE FITTING PO-
SITION OF THE REVERSE GEAR LIMIT CAM A BEFORE
REMOVAL, MARK THE FITTING POSITION. - DO NOT RE-
USE THE GASKET MENTIONED ABOVE.
GE - 558
Remove the gearbox cover
1. Remove the subassembly of the rpm indicator
shaft sleeve.
2. Remove the eight bolts of the gearbox cover,
together with the engine rear support bracket.
3. Slightly hit the ribbed section of the gearbox
cover. Then, take it out towards the operator.
- REMOVE THE GEARBOX COVER AND THE MAIN SHAFT
ONLY AFTER CHECKING FROM THE REAR PART IF
THERE IS AN OIL LEAKAGE, DEFORMATION, ETC., IN
THE DUST GUARD.
Removing the gearbox
1. Take out the oil seal from the secondary shaft.
2. Take out the oil drainage plug (magnetised) A.
Remove the residues that are collected on the
magnet.
3. Remove the bearing lock.
4. Detach the spring washer B of the primary shaft
radial ball bearing (from the rear part).
- REMOVE THE GEARBOX, AFTER CHECKING IF THERE
IS CLEARANCE BETWEEN THE INPUT SHAFT AND THE
PRIMARY SHAFT.
5. Remove the ten bolts of the gearbox (including
the two nuts which shall be removed from the low-
er side of the clutch box).
6. Slightly hit section C of the gearbox cover. Then,
take it out towards the operator.
Removing the gear control fork
1. Release the traction spring A.
2. Remove the compression spring and the ball,
taking out the hexagonal bolt with gasket B.
3. Remove the grooved pin of the traction spring
and then remove the gear control fork shaft.
4. Take out the reverse transmission gear C, the
thrust washer and reverse gear D.
GE - 559
5. Remove the gear control fork shaft of the 1st
and 2nd gear and, gradually, the gear control fork
shaft of the 3rd and 4th gear, following the proce-
dure described in previous points from 1 to 3.
- CHECK THE REVERSE GEAR CONTROL LEVER MOVE-
MENTS OF THE REVERSE GEAR CONTROL LEVER AND
THE CONTACT WIDTH BETWEEN THE GEAR CONTROL
FORK AND THE RIBBED SLEEVE.
- BEFORE REMOVING THE GEAR CONTROL FORK,
PLACE THE RELEVANT GEARS IN NEUTRAL.
- DURING PIN REMOVAL, MEASURE THE TRACTION
FORCE OF THE SPRING.
Main and transmission shafts
Removal
Removing the input and the secondary shaft
1. Take out the main shaft assembly with the nee-
dle bearing and the synchroniser ring.
N.B.
- MAKE SURE THAT EACH GEAR CAN BE PROPERLY.
2. Remove the reverse gear control lever, remov-
ing the three bolts.
3. Remove the plate locking the input shaft, by
taking out the three bolts.
4. While the input and the secondary shaft are held
with the hands, slide them off upwards.
Inspection
1. Measure the unloaded compression spring length for the gear control fork shafts and for the reverse
gear limit pin
SPRING SPECIFICATIONS
Unloaded length for gear control fork shafts 40 mm
Fitting load (N) for gear control fork shafts 47.33 N
Fitting height for gear control fork shafts 30 mm
Unloaded length for reverse gear limit pin 24 mm
GE - 560
Fitting load (N) for reverse gear limit pin 28.93 N
Fitting height for reverse gear limit pin 17 mm
2. Visually inspect the balls, to detect possible de-
formations or scoring.
3. Measure the length of the contact section be-
tween the selection internal lever shaft and the
gear fork heads.
Characteristic
Selection internal lever
Specified value: 15-0.002 mm-0.12 mm
Internal lever heads
Specified value: 15-0.02 mm-0.1 mm
Gear clutch control
Removal
Forks and heads of the gear
Inspection
1. Measure the outside diameter of the gear con-
trol fork shafts and the inside diameter of the seats.
Characteristic
Seat
Specified value: 13.0 +0.043 mm +0 mm
Shafts
Specified value: 13.0 -0.06 mm -0.07 mm
GE - 561
2. Measure the width of the contact sections be-
tween the heads of the gear and the gear internal
lever.
Characteristic
Heads of the gear
Gear internal lever:
Specified value: 12 -0.02 mm -0.12 mm
Reverse transmission gear
1. Visually check the chamfered section of the re-
verse transmission gear, and check for possible
damage.
2. Measure the diameter of the reverse transmis-
sion gear bushing seat.
3. Measure the outside diameter of the reverse
transmission gear shaft.
Inspect its surface, to check for possible scoring,
etc.
Characteristic
Specified value (d)
20 +0.061 mm+0.032 mm
Specified value (D)
20.0 +0 mm+0.013 mm
" S" type oil seal replacement
1. Remove the "S"oil seal.
2. Apply lithium grease onto the edge of the new
oil seal.
3. Fit the new oil seal, using a 26 mm bushing
(outside diameter of 35 mm), and a plastic ham-
mer.
GE - 562
Bimetallic bushing
1. Remove the oil seal.
2. Visually inspect the internal surface of the stam-
ped bimetallic bushing, and check for possible
discolouration or scoring.
3. Measure the inside diameter of the stamped bi-
metallic bushing.
4. Apply lithium grease onto the edge of the new
gasket.
5. Fit the new gasket.
N.B.
- THE HOLE DIAMETER SHALL MATCH THE SPECIFIED
VALUE. AN EXCESSIVELY LARGE DIAMETER CAUSES
OIL LEAKAGE. THE BIMETALLIC BUSHING SHALL BE RE-
PLACED TOGETHER WITH THE GEARBOX COVER.
Specific tooling
020200Y Extractor
Characteristic
Specified value:
30.0 +0.021 mm +0 mm
Replacement of gearshift lever and gear com-
ponents
Removal
1. Remove the sleeve of the selection lever.
2. Remove the sealing cap (if necessary).
3. Remove the T oil seal.
N.B.
- DO NOT REUSE THE SEALING CAP AND THE OIL SEAL
PREVIOUSLY REMOVED .
Installation
1. Fit a new sealing cap, as shown in the figure on the right.
2. Fit a new T oil seal, as shown in the figure on the right.
3. Make sure that the protruding part A of the T oil seal complies with the specified value.
4. Check there is electric continuity between the switch and the reverse bulb.
N.B.
- IF THE PROTRUDING PART EXCEEDS THE VALUE SPECIFIED ABOVE (OR 5.3 MM), IT CAN
CAUSE OIL LEAKAGE.
Characteristic
Specified value:
5 0.3 mm
GE - 563
Inlet shaft
COMPONENTS
1. Circlip *
2. Radial ball bearing (front)
3. Input shaft
4. Needle bearing
5. 5th gear
6. Synchronisation ring No. 1
7. Synchroniser elastic key
8. Synchroniser hub assembly No. 3
9. Synchroniser movement key
10. Hub key stop
11. Circlip *
12. Needle bearing
13. 3rd gear
18. Circlip *
GE - 564
20. Needle bearing (open)
INPUT SHAFT - COMPONENTS
1. Circlip *
This component is the same as part 18. Spring washer to be selected according to thickness.
2. Radial ball bearing
Fit the bearing so that the side having the gasket is at the front part.
3. Input shaft
Needle bearing rolling section:
D =31.971 - 31.991 mm, measure at two points.
Needle bearing rear end section:
D =19.966 - 19.984 mm
Never expand the opening of the bearing with a value exceeding the input shaft diameter +5 mm, upon
fitting and removal.
The opening of the bearing shall not exceed 37 mm.
5. 5th gear
Hole diameter: 37.00 - 37.025 mm
Width: 27.82 - 27.88 mm
Axial clearance: 0.1 - 0.4 mm
Components 6, 14 and 19 are identical and are used in different positions.
The clearance between the gear and the synchronisation ring is:
0.95 - 1.35 mm
Components 7, and 15 are identical and are used in different positions.
Make sure that the key openings are fitted displaced one from the other.
Hub section thickness: 12.37 -12.43 mm
Sleeves 8, and 16 are identical and are used in different positions.
Nevertheless, pay special attention not to mix sleeves with other components, since the hub and the
sleeve are fitted together as a set.
Fit the hub so that the grooved side for the hub oil is at the front side, precisely from the 5th gear side.
The sleeve, instead, does not have a correct fitting direction that shall be followed. Nevertheless, make
sure to align the missing teeth sections, which are in three different positions, when coupling the hub
and sleeve.
GE - 565
Then, a total of 6 pieces is used simultaneously.
Thickness: 4.6 - 4.8 mm
10. Hub key stop
Fit this stop so that the flat part is located at the front; and the oil grooved side is located at the back.
This component is equal to the component 23 of the secondary shaft.
*11. Circlip
It required to select thickness.
This component is equal to the component 7 of the secondary shaft.
12. Needle bearing
Hole diameter: 37.00 - 37.025 mm
13. 3rd gear
Width: 37.95 - 37.98 mm
Number of gear teeth: 32
Outside diameter: 61 mm
The clearance between the gear and the synchronisation ring is:
0.95 - 1.35 mm
Hub section thickness: 18.52 - 18.58 mm
Fit the hub so that the grooved side for the hub oil is at the front side, precisely from the 3rd gear side.
Make sure to align the missing teeth sections, which are in three different positions, when coupling the
hub and sleeve.
The sleeve, instead, does not have a correct fitting direction that shall be followed.
Gear control fork groove width: 7.05 - 7.12 mm
Then, a total of 6 pieces is used simultaneously.
*18. Circlip
This component is common in position 1
GE - 566
Spring washer to be selected according to thickness.
Refer to components 6 and 14
This needle bearing is placed between the input shaft and the main shaft.
* -1 When circlip 11 is removed, components from 4 to 10 can be removed together.
* -2 When circlip 18 is removed, components from 12 to 17 can be removed together.
Inspections before removal
1. Measure the contact section of the gear control
fork and of the hub sleeve for the 3rd gear A and
for the 5th gear B
3RD GEAR (A) AND 5TH GEAR (A)
Fork Specification value: 7-0.1mm-0.3mm
Admissible limit: 6.6
Hub sleeve Specification value: 7 +0.12 mm -0.2 mm
Limit: 7.2
2. Measure and adjust thrust clearance for the 3rd
gear C and the 5th gear D, using a thickness
gauge.
- MAKE SURE THAT THE THRUST CLEARANCE IS MEAS-
URED AT DIFFERENT POINTS.
- IF THE THRUST CLEARANCE MEASUREMENT DOES
NOT COMPLY WITH SPECIFICATIONS, REMOVE THE IN-
PUT SHAFT ASSEMBLY.
Characteristic
Gear C
Specified value: 0.10 - 0.52 mm
Gear D
GE - 567
Removal
1. With soft shoes, close the input shaft assembly
in a vice so as to avoid damaging the grooved
section.
2. Remove the shaft circlip from the rear part.
Synchroniser hub assembly No. 2
Synchronisation ring No. 1
3rd gear
3. As a reference during fitting, measure and ad-
just the size of the shaft spring washer just re-
moved.
- THE PARTS LISTED BELOW SHALL BE REMOVED, TAK-
ING OUT THE INPUT SHAFT BY PRESSING AND HOLDING
THE SECTION OF THE 3rd GEAR WITH THE SPECIAL
TOOL.
Specific tooling
020206Y Extractor
5. Remove the needle bearing.
6. Remove the circlip of the shaft.
7. As a reference during fitting, measure and ad-
just the size of the shaft spring washer just re-
moved.
8. Remove stop of the gear hub sleeve.
5th gear
- THE PARTS LISTED BELOW SHALL BE REMOVED, TAK-
ING OUT THE INPUT SHAFT BY PRESSING AND HOLDING
THE SECTION OF THE 5th GEAR WITH THE SPECIAL
TOOL.
Specific tooling
020206Y Extractor
GE - 568
10. Remove the needle bearing (open).
- NEVER EXPAND OPENING (B) OF THE BEARING WITH A
VALUE EXCEEDING THE INPUT SHAFT DIAMETER + 5
MM, UPON FITTING AND REMOVAL.
11. Remove the circlip of the shaft.
12. Measure the thickness and adjust the values obtained from the circlip just removed. These data are
useful as a reference during the fitting phase.
13. Remove the radial bearing from the front side.
Inspection
1. Check clearance between the gear conical sec-
tion and the synchronisation rings.
Characteristic
Specification value:
0.95 -1.35 mm
2. Measure the input shaft outside diameter
matching sections A, B and C, according to the
indications in the figure.
3. Visually inspect sections A, B and C, to highlight
possible scoring or discolouration.
Characteristic
A and B
Specification values: 32-0.0090mm-0.029mm
C
Specification values: 20-0.0016mm-0.034mm
GE - 569
4. Measure the outside diameter of synchroniser
No. 2 of the third gear A and of synchroniser No.
3 of the fifth gear B and the inside diameter of both
hub sleeves.
- IF ANY PART WHICH EXCEEDS THE VALUES OF THE
TABLE SHOULD BE EMPLOYED, THAT WOULD CAUSE
ABNORMAL NOISE. THEREFORE, MAKE SURE THAT IN
ADDITION TO THE PARTS OUT OF TOLERANCE ALSO
THE OTHER ARE REPLACED.
Classification No. 2 - (Yellow)
A and B: 57.78 - 57.84 mm
Hub sleeve 57.871 - 57.97 mm
Classification No. 1 - (No colour)
A and B: 57.68 - 57.74 mm
Hub sleeve 57.771 - 57.87 mm
Classification No. 3 - (White)
A and B: 57 58 - 57.64 mm
Hub sleeve 57.67 - 57.77 mm
5. Measure the hub thickness of synchroniser No.
2 C and No. 3 D.
Characteristic
C
Specified value: 18.55 0.03 mm
D
Specified value 12.4 0.03 mm
6. Measure the height of the gear hub sleeve stop.
Characteristic
Size A:
Specified value:
7.2 +0.05 mm
7.2 - 0.01 mm
GE - 570
7. Measure the thickness and the inside diameter
of the third and the fifth gear
Characteristic
3rd gear A
5th gear B
3rd gear C
5th gear D
27.85 0.03 mm
8. Measure the height of the synchronised move-
ment key.
9. Visually inspect the synchroniser movement
key, to highlight possible signs of wear or damage.
- THE SIX SYNCHRONISER MOVEMENT KEYS, FITTED ON
THE INPUT SHAFT, ARE EQUAL.
Characteristic
Specified value
5 - 0.2 mm - 0.4 mm
Fitting
Initial operations
1. Fit the needle bearing and apply engine oil.
N.B.
- UPON FITTING, APPLY ENGINE OIL ONTO THE COMPO-
NENTS.
- NEVER REUSE COMPONENTS MARKED WITH AN AS-
TERISK
- NEVER EXPAND OPENING (B) OF THE BEARING WITH A
VALUE EXCEEDING THE INPUT SHAFT DIAMETER + 5
MM, UPON FITTING AND REMOVAL.
2. Fit the fifth gear and the synchronisation ring to
the input shaft.
3. Fit the synchronised movement key and the rel-
evant elastic key to the hub, as shown in the figure.
- The same hub sleeve is used for the third or
fourth gear.
Nevertheless, the hub of third and fourth gear dif-
fers due to its shape.
- MAKE SURE THAT THE KEY OPENINGS ARE FITTED
DISPLACED ONE FROM THE OTHER.
GE - 571
- MAKE SURE TO ALIGN THE MISSING TEETH SECTIONS,
WHICH ARE IN THREE DIFFERENT POSITIONS, WHEN
FITTING THE HUB AND SLEEVE.
- THE SAME HUB SLEEVE IS USED FOR THE THIRD AND
THE FOURTH GEAR; NEVERTHELESS, THE HUB OF THE
THIRD AND THE FOURTH GEAR DIFFERS DUE TO ITS
SHAPE.
4. Make sure that the grooved area of the protrud-
ing part of the synchroniser hub No. 3 faces to the
front (for example: the fifth gear) and press slightly.
- MAKE SURE THAT THE SYNCHRONISER RINGS ARE
ALIGNED WITH THE GROOVES OF THE MOVEMENT KEYS
(THREE POINTS), WHILE THE SYNCHRONISER HUB No. 3
IS FITTED BY PRESSURE.
5. Fit the stop of the hub sleeve.
- MAKE SURE THAT THE GROOVED SECTOR FOR LOCK-
ING THE FIFTH MOVEMENT KEY IS FACING THE THIRD
GEAR.
6. Selection procedure of the new shaft spring
washer
select the new shaft spring washer,
which has the same thickness as that
measured at the time of removal, or a
thinner shaft spring washer. Then, fit
the spring washer (selected in this
way) in the input shaft fitting groove.
Measure clearance, using a thickness
gauge, as shown in the figure.
Select a shaft spring washer, having clearance near zero or zero which can be identified
easily, as indicated below.
Make sure that clearance between the movement key locking and the shaft spring washer complies
with specified values.
P/N 90045-20263 (No colour) Thickness: 2.06 mm
P/N 90045-20264 (Brown) Thickness: 2.02 mm
P/N 90045-20265 (Blue) Thickness: 1.98 mm
GE - 572
* THE SPRING WASHERS INDICATED IN THE TABLE ABOVE ARE EQUAL TO THOSE USED
WHEN THE SECONDARY SHAFT HUB IS FITTED.
Characteristic
Clearance:
Specified value: 0
Value allowed: less than 0.16 mm
7. Fit the needle bearing and lubricate with engine
oil.
8. Fit the third gear and the synchronisation ring.
9. Fit the synchroniser elastic key and movement
key on the synchroniser hub assembly No. 2.
10. Make sure that the grooved section A of the
synchroniser hub assembly No. 2 is facing the third
gear side.
- FOR THE CORRECT USE OF THE HUB SLEEVE, REFER
TO POINT 3. - MAKE SURE THAT THE SYNCHRONISER
RINGS ARE ALIGNED WITH THE GROOVES OF THE
MOVEMENT KEYS (THREE POINTS), WHILE THE SYN-
CHRONISER HUB No. 3 IS FITTED BY PRESSURE.
11. Selection procedure of the new shaft spring
washer
For the selection procedure of the new
shaft spring washer, refer to the proce-
dure described above in reference with
the following values.
Make sure that clearance between the
hub and the shaft spring washer com-
plies with the values specified.
GE - 573
- MAKE SURE THAT THE GASKET OF THE RADIAL BALL
BEARING IS FACING THE FRONT PART.
- DO NOT LET FALL THE SYNCHRONISATION RING AND
THE HUB SLEEVE, WHILE THE RADIAL BALL BEARING IS
BEING FITTED BY PRESSURE.
- THE RADIAL BALL BEARING SHALL BE FITTED FIRST.
Characteristic
Clearance:
Specified value: 0
12. Fit the ball bearing by pressure.
13. Fit the elastic ring of the shaft (component to
be selected) following the same procedure indica-
ted in point 11.
- MAKE SURE THAT THE GASKET OF THE RADIAL BALL
BEARING IS FACING THE FRONT PART.
- DO NOT LET FALL THE SYNCHRONISATION RING AND
THE HUB SLEEVE, WHILE THE RADIAL BALL BEARING IS
BEING FITTED BY PRESSURE.
- THE RADIAL BALL BEARING SHALL BE FITTED FIRST.
Main shaft
Removal
1. Remove the radial ball bearing (from the rear
part), with the following special tool:
2. Take out the odometer pinion.
3. To avoid damage, lock the main shaft grooved
section in a vice with soft shoes.
GE - 574
4. Remove the lock nut with a 32 mm wrench.
- DO NOT REUSE THE LOCK NUT REMOVED.
5. Remove the radial ball bearing with the following
special tool:
Specific tooling
020206Y Extractor
Inspection
1. Check clearance between the synchronisation
ring and the gear conical section.
2. Visually check the possible worn areas and
damage of the gear and the main shaft grooved
section.
Characteristic
0.95 - 1.35 mm
3. When the external and central part of the radial
ball bearing internal rotation seat is turned with the
fingers, as shown in the figure, the rotation must
be smooth and without jamming.
GE - 575
Fitting
1. Press on radial ball bearing internal rotation
seat.
- Make sure that the locking section (this is the part
which has the sealing gasket) of the radial ball
bearing is facing towards the rear part.
THE RADIAL BALL BEARING CAN BE FITTED BY PRES-
SURE, USING THE SPECIAL TOOL OR A PIPE TO PRESS
ON THE INTERNAL ROTATION SEAT.
2. Fit a 32 mm torque wrench in the main shaft.
3. To avoid damage, lock the main shaft grooved
section in a vice with soft shoes.
4. Tighten the lock nut with a torque wrench.
Lock nut - Main shaft 177216
5. Tighten the new lock nut.
- AFTER TIGHTENING THE LOCK NUT, PUNCH THE REL-
EVANT SAFETY PLATE. FOR A PROPER LOCKING,
PUNCH IN A VERTICAL DIRECTION WITH RESPECT TO
THE MAIN SHAFT (SEE THE FIGURE ON THE RIGHT - UP).
- THE LOCK NUT CAN BE LOOSENED (SEE THE FIGURE
ON THE RIGHT - AT THE CENTRE AND AT THE BOTTOM)
DUE TO INCORRECT PUNCHING.
6. Fit the odometer pinion.
7. Press on the radial ball bearing internal rotation
seat (to be used at the rear part), with the following
steel tool with pipe shape.
N.B.
FROM THE MOMENT THAT THE ODOMETER PINION IS
MADE OF NYLON, IT CAN BE DEFORMED IF THE RADIAL
BALL BEARING (TO BE USED AT THE REAR PART) IS
DEEPLY THRUST BY PRESSURE MORE THAN SPECIFIED
(93.00 mm).
THEREFORE, PAY SPECIAL ATTENTION WHILE PRESS-
ING ON THE RADIAL BALL BEARING (TO BE USED AT
THE REAR PART). WHEN THE BEARING COMES INTO
CONTACT WITH THE ODOMETER PINION, STOP PRESS-
ING. NOW, MAKE SURE THERE IS A 93.00 mm DEPTH.
FOR THIS OPERATION, IT IS ADVISABLE TO USE THE
FOLLOWING TOOL TO FIT BY PRESSURE A HAVING
THE DIMENSIONS DESCRIBED BELOW.
Characteristic
Total depth
GE - 576
93.00 mm
Outside diameter
35.00 mm
Inside diameter
25.00 mm
Transmission shaft
Components
1. Circlip *
3. Thrust washer of the 1st gear
4. Circlip *
5. 1st sub-gear
6. Circlip
7. Needle bearing
8. 1st gear
14. Needle bearing
15. 2nd gear
16. Conical spring washer *
17. 2nd sub-gear
18. Shaft spring washer
GE - 577
19. Transmission gear
21. Circlip *
SECONDARY SHAFT COMPONENTS
* 1 Circlip
Type to be selected.
2 Radial ball bearing
Bearing without gasket.
3 Thrust washer of the 1st gear
Thickness =3.97 - 4.03
Fit the washer so that the protruding part is facing to the front; and the oil grooved part is facing towards
the 1st gear.
Thrust clearance of the 1st gear =0.1 - 0.52 mm
* 4 Circlip * - 1
5 1st sub - gear
Components 4 and 18 have the same function. Components 4 and 18 are generally considered as
assembled parts.
Components 6 and 16 have the same function.
6 Conical spring washer
This bearing is interchangeable with part 12 of the input shaft.
7. Needle bearing
Inside diameter: 37.00 - 37.025 mm
8 1st gear
Real thickness: 27.31 - 27.37 mm
Clearance regarding the synchronisation ring: 0.95 - 1.35 mm
Limit: 0.9 mm
9 Synchronisation ring No. 2
The synchronisation ring No. 2 is not interchangeable with part 13. In order to distinguish it from part
13 teeth are eliminated in three different points.
10 Synchroniser elastic key
11 Synchroniser hub assembly No. 1
The hub and sleeve (transmission gear) are fitted at set level.
Real width of the hub: 26.97 - 27.03 mm
Fit the hub assembly so that the side having the wider protruding parts, is facing to the front.
As regards the sleeve (transmission gear), make sure that the gear control fork groove is facing the
front.
GE - 578
Fork groove width: 10.05 - 10.12 mm *-2
12 Synchroniser movement key
Thickness =5.0 - 5.2 mm, composed by 3 pieces.
13 Synchronisation ring No. 3
Not interchangeable with component 9
14 Needle bearing
This bearing is interchangeable with bearing 4 of the input shaft.
Never expand the opening of the bearing with a value exceeding the input shaft diameter +5 mm, upon
fitting and removal.
The opening of the bearing shall not exceed 37 mm.
15 2nd gear
Inside diameter: 37.00 - 37.025 mm
Real thickness: 36.27 - 36.33 mm
Clearance regarding the synchronisation ring:
0.95 - 1.35 mm
Limit: 0.9 mm
16 Conical spring washer
Components 6 and 16 have the same function.
Secure each part of the 2nd gear so that the part of the washer having the larger diameter, is facing
the sub-gear side.
17 2nd sub - gear
Components 15 and 17 are considered parts assembled together with ring 18.
* 18 Shaft spring washer
Components 4 and 18 are identical.
19 Transmission gear
Outside diameter of the bearing rolling section:
31.971 - 31.991 mm
20 Radial ball bearing
Fit the bearing so that the side having the gasket is facing backwards.
* 21 Circlip
This component is identical to part 11 of the input shaft: Part selected due to thickness.
* - 1 When spring washer 1 is removed, all components up to 8 can be removed together.
* - 2 When spring washer 18 is removed, all components from 10 to 18 can be removed together.
GE - 579
Removal
1. To avoid damage, lock the secondary shaft
grooved section in a vice with soft shoes.
2. Remove the shaft circlip (part indicated in the
figure).
3. Measure the shaft circlip immediately after it has
been removed. Record the values measured.
This measurement will be a reference at the mo-
ment of fitting.
4. Remove the following parts, slightly pressing on
the secondary shaft by means of a specific pipe.
Radial ball bearing
Thrust washer of the 1st gear
1st gear
Needle bearing
- THE COMPONENTS DESCRIBED ABOVE, CAN BE RE-
MOVED BY SLIGHTLY PRESSING ON THE SECONDARY
SHAFT, WHILE THE 1ST GEAR IS SUPPORTED BY MEANS
OF THE SPECIAL TOOL.
Specific tooling
020206Y Extractor
5.Remove the shaft circlip (part indicated in the
figure).
6. Measure the shaft circlip immediately after it has
been removed. Record the values measured.
GE - 580
7. Remove the following components:
2nd gear with sub-gear
- THE COMPONENTS DESCRIBED ABOVE, CAN BE RE-
MOVED BY SLIGHTLY PRESSING ON THE SECONDARY
SHAFT, WHILE THE 2nd GEAR (SUB-GEAR SURFACE) IS
SUPPORTED BY MEANS OF THE TOOL INDICATED
ABOVE.
8. Remove the needle bearing.
- NEVER EXPAND OPENING (A) OF THE BEARING WITH A
VALUE EXCEEDING THE SECONDARY SHAFT DIAMETER
+ 5 MM, UPON FITTING AND REMOVAL. FAILURE TO OB-
SERVE THIS CONDITION CAN CAUSE ABNORMAL NOISE
OF THE GEAR.
Inspection
1. Measure the height of synchronised gear elastic
keys. Specification value: 5.1 0.1 mm
2. Visually inspect the synchronised gear elastic
key spring, to highlight possible damage or distor-
tions.
3. Measure the outside diameter of the secondary
shaft, corresponding to sections (A) and (B)
4. Visually check the sections (A) and (B), to high-
light the presence of possible scores and wear.
Characteristic
(A)
Specified value: 32 - 0 0029 mm- 0.0029;mm
(B)
Specified value: 32 - 0 0029 mm- 0.0029;mm
5. Measure the thickness of the thrust washer of
the 1st gear.
Characteristic
4 0.03 mm
GE - 581
6. Measure the outside diameter sizes of the syn-
chroniser hub No. 1 (A) and the inside diameter
(B) of the sleeve.
(Reference information)
The components (A) and (B) are available only as
kits. The synchroniser hub end surface has an
identification mark.
Classification No. 2 - Yellow
(A): 69.78-69.84
(B): 69.871-69.97
Classification No. 1 - No colour
(A): 69.68-69.74
(B): 69771-69.87
Classification No.. 3 - White
(A): 69.58-69.64
(B): 69.67-69.77
- PARTS (A) AND (B) SHALL BE REPLACED TOGETHER.
7. Measure thickness (A) of the synchroniser hub
No. 1.
8. Measure the inside diameter of the 1st and the
2nd gear.
Characteristic
27 0.03 mm
1st gear (A)
Specified value: 37.0 +0.025+0 mm
2nd gear (B)
Specified value: 37.0 +0.025+0 mm
9. Measure the thickness of the 1st and the 2nd
gear.
Characteristic
1st gear (C)
2nd gear (D)
GE - 582
Replacing the conical spring washer
1. Lock the 1st gear, together with a square clamp,
in a vice, as shown in the figure.
2. Remove the conical spring washer and the sub
gear, removing the spring washer of the shaft.
Fitting
- During the fitting phase of the secondary shaft,
lubricate with engine oil and assemble each part.
1. Fit the needle bearing.
2. Apply engine oil onto the external peripheral
area of the roller bearing and fit the 2nd gear into
the secondary shaft.
WARNING
- NEVER EXPAND OPENING A OF THE BEARING WITH A
VALUE EXCEEDING THE SECONDARY SHAFT DIAMETER
+ 5 MM, UPON FITTING AND REMOVAL.
2. Apply engine oil onto the external peripheral
area of the needle bearing and fit the 2nd gear into
the secondary shaft.
3. Place the synchronisation ring No. 3 on the syn-
chroniser hub No. 1.
4. Fit the synchronisation ring No. 3 on the syn-
chroniser No. 1.
5. Fit the synchronised movement key and the
synchronised gear elastic key in the synchroniser
hub assembly No. 1.
N.B.
- THE EXTERNAL APPEARANCE OF THE SYNCHRONISA-
TION RING No. 3 FOR THE 2nd GEAR B IS DIFFERENT
FROM THAT ONE OF THE SYNCHRONISATION RING No.
2 (FOR THE 1st GEAR A), AS IT IS SHOWN IN THE FIGURE
ON THE RIGHT.
N.B.
- MAKE SURE THAT THE KEY OPENINGS ARE FITTED
DISPLACED ONE FROM THE OTHER.
- WHEN FITTING THE HUB AND THE HUB SLEEVE, MAKE
SURE TO ALIGN SECTIONS OF THE THREE TEETH MISS-
ING.
GE - 583
6. Before pressing on the synchroniser hub as-
sembly No. 1, make sure that the hub protruding
part A is facing to the front (the hub sleeve has a
groove of the gear control fork).
7. Apply engine oil onto the conical section of the
2nd gear.
8. Apply engine oil onto the grooved section.
9. Align the grooved section. Slightly press the hub
assembly of synchroniser No. 2.
N.B.
- WHILE SLIGHTLY PRESSING ON THE SYNCHRONISER
HUB ASSEMBLY No. 2 IN ORDER TO INSERT IT IN THE
SECONDARY SHAFT, MAKE SURE THAT THE MOVEMENT
KEY FITTED ON THE HUB IS ALIGNED WITH THE GROOVE
PROVIDED BY THE SAME KEY, WHICH IS PLACED ON
THE SYNCHRONISATION RING.
10. Sequence for selection of a new shaft spring
washer.
Select the new shaft spring washer,
which has the same thickness as that
measured at the time of removal, or a
thinner shaft spring washer. Then, fit
the spring washer (selected in this
way) in the secondary shaft fitting
groove.
Measure clearance, using a thickness
gauge, as shown in the figure.
Select a shaft spring washer, having
clearance near zero or zero and which
can be identified easily, as indicated
below. Then, proceed to fit it.
Make sure that clearance complies
with the specified values.
Characteristic
Clearance:
Specified value: 0
GE - 584
11. Fit the needle bearing. Apply engine oil onto
the external ring of this bearing.
12. Place the synchronisation key No. 2 (the ring
with teeth missing).
13. Fit the 1st gear with the sub-gear fitted.
14. Fit the thrust washer of the 1st gear.
WARNING
- MAKE USE THAT THE PROTRUDING PART A OF THE
THRUST WASHER OF THE 1st GEAR IS FACING TO THE
FRONT.
15. Push with pressure on the radial ball bearing
(this bearing does not have gaskets).
16. Sequence to select a new shaft spring washer
For the selection procedure of a new
shaft spring washer, refer to the proce-
dure described above.
Make sure that clearance complies
with the specified values.
Characteristic
Clearance:
Specified value: 0
GE - 585
Secondary shaft - inspection before removal
1. Measure the length of the contact section of the
hub assembly of synchroniser No. 1 (B) and of the
first and second gear control fork (A)
Characteristic
(A)
Specification value: 10 -0.1 mm -0.3 mm
(A)
(B)
Specification value: 10 +0.12 mm +0.05 mm
(B)
2. Measure and adjust the axial clearance of the 1st gear (C) and of the 2nd gear (D), as shown in the
figure.
- BEFORE STARTING REMOVAL, MAKE SURE OF MEASURING THE AXIAL CLEARANCE AT
DIFFERENT POINTS.
- IF THE AXIAL CLEARANCE MEASURED EXCEEDS THE SPECIFIED VALUE IN THE TABLE
BELOW, REMOVE THE SECONDARY SHAFT.
Characteristic
1st gear (C)
2nd gear (D)
Inspection - 2
1. Measure the height of the conical spring washer.
2. Place the new conical spring washer 1, the sub-
gear on the 1st gear.
3. Make sure that the convex side of the conical
spring washer is facing towards the sub-gear, as
Characteristic
2.01 mm
Admissible limit:
GE - 586
1.04 mm
4. Fit the new shaft circlip, pressing on the conical
spring washer, by means of the square clamp.
5. Following the same procedure described above,
replace the conical spring washer of the 2nd sub-
gear.
6. Make sure that the conical spring washer con-
vex side of gear No. 2 (1) is facing towards the sub-
gear side, as shown in the figure.
Fitting
Installation
Initial operations
1. For a simpler fitting of the shaft assemblies in-
side the gearbox, align the teeth of the 1st and 2nd
sub-gear with those of the input shaft gear. Each
single sub-gear has one tooth less with respect to
the main gear;
N.B.
- BEFORE FITTING THE SECONDARY SHAFT ASSEMBLY
AND THE INPUT SHAFT ASSEMBLY INSIDE THE GEAR-
BOX, MAKE SURE THAT EACH GEAR IS IN NEUTRAL
POSITION.
2. While the input and the secondary shaft assem-
blies are held with both hands, fit them inside the
clutch housing.
3. Tighten the plate locking the input shaft bearing
with the three bolts.
4. Place the two pieces of the plates locking the
gear, from the clutch housing part.
N.B.
- PAY ATTENTION NOT TO DAMAGE THE S TYPE OIL
SEAL, WHILE THE SHAFTS ARE FITTED.
GE - 587
Rear bearing lock - Gearbox 1522
5. Attach the tension spring to the plate locking the
input shaft bearing.
6. Tighten the reverse gear control lever with three
bolts.
Checking that the reverse gear control lever
moves freely
1.Checking that the reverse gear control lever
moves freely
Lift the reverse gear control lever pin
with the fingers.
Make sure that the reverse gear control
lever pin falls freely due to its weight,
when released.
2. Fit the reverse transmission gear A , shaft C and
the thrust washer B as shown in the figure.
- DURING THE FITTING PHASE, INSTALL THE LOCKING
PIN, WHICH PREVENTS THE TRANSMISSION GEAR
SHAFT ROTATION FROM THE CLUTCH HOUSING SEC-
TION TO THE GROOVED SECTION.
- MAKE SURE THAT THE CHAMFERED SIDE OF THE
GEAR AND THE THRUST WASHER (NYLON) IS FACING
UPWARDS (OR THE REAR SIDE).
3. The following three shafts of the gear control
fork, are different from each other by length, as
shown in the figure on the right. +
GEAR FORK SHAFTS
Shaft No.. 1: 1st and 2nd - total length: 224.00 mm
Shaft No.. 2: 3rd and 4th - total length: 259.00 mm
Shaft No.. 3: 5th and reverse gear - total length:
265.00 mm
GE - 588
N.B.
- PAY ATTENTION NOT TO MAKE MISTAKES DURING FIT-
TING OF THESE THREE SHAFTS.
4. The gear control fork and the heads of the gear
are different by their external image, as it is shown
in the figure. Therefore, pay attention not to make
any mistakes while fitting this fork and this gear
head.
Fork No. 1: 1st and 2nd
Fork No. 2: 3rd and 4th
Fork No. 3: 5th and reverse gear
- IT IS ADVISABLE TO MAKE A TEMPORARY FITTING
(FROM BENCH) OF THE GEAR CONTROL FORK AND REL-
EVANT HEADS, THEN CHECK THAT THE COUPLING AND
FITTING DIRECTION ARE CORRECT. THEN PROCEED
WITH THE FITTING.
Fitting the gear control fork and the relevant
shaft
Apply engine oil where it is required. Carry out op-
erations according to the procedures provided be-
low. Proceed as follows
1. Insert temporarily a new spring grooved pin in
all the gear control forks and heads, so that the
shaft can be easily guided.
2. Fit the gear control fork of the third and the fourth
gear on the hub sleeve and insert the shaft of this
fork.
- MAKE SURE THAT THE GEAR IS IN NEUTRAL POSITION.
- IN ORDER TO INSERT A SPRING GROOVED PIN WITH-
OUT JAMMING, IT IS ADVISABLE TO PREPARE A GUIDE
PIN WITH A 4.0 MM OUTSIDE DIAMETER AND A 50.00 MM
LENGTH.
- CARRY OUT FITTING OPERATIONS AFTER CHECKING
THE CORRECT FITTING POSITION OF THE GEAR CON-
TROL FORK AND HEAD AND THE RELEVANT PROPER
POSITION REGARDING THE GEARS
GE - 589
3. Insert a guide pin, or anything equivalent, at the
rear part of the control fork groove, as a fitting
guide for the spring grooved pin.
4. Fit a new spring grooved pin.
5. Following the steps of points 2 and 3, insert the
head of the third and the fourth gear.
6. Fit the gear control fork of the first and the sec-
ond gear in the hub sleeve and insert the fork shaft
of the first and the second gear.
7. As regards fitting the control fork of the first and
the second gear and the relevant head, refer to the
operations described above.
8. Insert the head of the fifth and reverse gear in
the gear control fork shaft.
9. As regards fitting the control fork of the fifth and
reverse gear and relevant heads, refer to points 2
and 3 described above.
10. Attach the tension spring to the reverse gear
control lever.
11. Fit the three balls and relevant compression
springs and tighten the three bolts, after interpos-
ing a new gasket.
12. Fit the primary shaft with the synchronisation
ring and the needle bearing.
Gear control fork shaft screw - Clutch hous-
ing 1930
Final operations
1. Clean the contact surface between the clutch
housing and the gearbox, using solvent or a similar
product.
- MAKE SURE THAT THE OIL RECEPTION DUCT IS PROP-
ERLY FITTED (LOCKED MECHANICALLY) INSIDE THE
GEARBOX.
GE - 590
2. Apply the following liquid sealant onto the gear-
box surface, as shown in the figure.
3. Fit the gearbox quickly.
4. Tighten the ten bolts between the gearbox and
the clutch housing.
Three Bond 1216 Specific sealant
.
Characteristic
Nozzle inside diameter:
0.9 mm
Gearbox cover - Gearbox 15 22
5. After interposing the new gasket, tighten hex-
agonal bolt (A) of the transmission gear shaft of
the reverse gear.
6. Lock the rear bearing stop device with the three
bolts.
7. Place the magnetised drainage screw (A) of the
gear and the circlip (B)
8. Fit the oil deflector inside secondary shaft.
Reverse transmission gear shaft screw - Gear-
box 19 31 Rear bearing lock for gearbox 15 22
Nm
9. Clean the contact surface between the gearbox
and gear cover, using solvent or a similar product.
10. Apply the following liquid sealant onto the re-
bound housing surface, as shown in the figure.
- MAKE SURE THAT THE OIL SUCTION PIPE IS FITTED
(LOCKED) FIRMLY INSIDE THE GEAR COVER
Three Bond 1216 Specific sealant
.
Characteristic
Nozzle inside diameter:
0.9 mm
GE - 591
11. Fit the gear cover with the engine rear fitting
bracket quickly. Then, lock it with the eight bolts.
12. Fit the rpm indicator gear assembly.
13. Tighten the plate locking the rpm indicator gear
with the bolt.
14. Fit the clutch components.
Engine fitting rear bracket for gearbox cover 29
44 Nm Rpm indicator locking plate - Gearbox
cover 7 10
15. Fit the reverse gear limit cam (A) and the gear-
shift lever (B) as shown in the figure.
- MAKE SURE THAT THE LIMIT CAM OF THE REVERSE
GEAR IS FITTED PROPERLY. FAILURE TO OBSERVE THIS
WARNING CAN CAUSE THE REVERSE GEAR DISEN-
GAGEMENT.
16. Fit the gear lever sleeve and the gearshift lever
shaft properly, as shown in the figure.
17. Tighten the subassembly of the selection lever
shaft with the four bolts, after fitting a new gasket.
N.B.
- MAKE SURE THAT THE AIR BLEEDING SECTION A OF
THE SLEEVE, IS FACING DOWNWARDS.
N.B.
- MAKE SURE THAT THE GUIDE BOLT C IS PLACED AS
SHOWN IN THE FIGURE.
gear selection lever 15 - 22 Nm
18. Fit the ball and the compression spring, and
tighten the reverse gear limit pin locking B with
a new gasket by interposing it.
19. Make sure that the selection lever and the
gears move without jamming.
Fitting the gear assembly on the vehicle
1. While holding the gearbox assembly with a suitable jack, or anything equivalent, fit it to the vehicle
and tighten the connection bolts.
GE - 592
2. Tighten the rear support bracket of the engine to the chassis by means of bolts.
3. Tighten the clutch housing with bolts.
- THE SAME INSTRUCTIONS APPLICABLE TO GEAR INSTALLATION (FITTING) ARE VALID TO
FIT THE GEAR ASSEMBLY ON THE VEHICLE. ONLY FEW POINTS HAVE BEEN MODIFIED RE-
GARDING THE PREVIOUS PROCEDURE. THEREFORE, ONLY THE MAIN POINTS OF THE PRO-
CEDURE ARE INDICATED BELOW.
Direct connection bolt - Transmission 4969 Rear engine support bracket - Chassis 49 69
Clutch lower cover - Gearbox 47
4. Connect the transmission flange with the differ-
ential flange in a position in which the transmission
flange identification mark B comes as near as pos-
sible to the differential flange identification mark
C (or in a position in which size A becomes as
small as possible).
5. Tighten the four bolts of the propeller shaft.
6. Remove the filler cap with its gasket.
7. Fill with new gearbox oil. (Reference informa-
tion)
8. Fit a new gasket and then tighten the filler cap.
(Quantity of gearbox oil required until it starts to
overflow from the filler cap).
AGIP ROTRA MP 80W-90 Transmission oil
Characteristic
Gearbox oil capacity:
1.0 1.1 l
Propeller shaft - Rear differential flange 3954
Gearbox cover for filler cap 30 49
GE - 593
INDEX OF TOPICS
DIFFERENTIAL DI
Differential
This section of the manual provides information to check differential correct operation.
Vista in sezione
Main removal operations
(1) Position the axle on the bench.
2) Remove the half-shafts.
(3) Remove the differential cover and the differential housing.
(4) Remove the flange, the bevel pinion and the sealing ring.
(5) Replace the pinion spacer.
Main fitting operations
(1) Fit the bevel pinion, a new sealing ring, the flange, a new O-ring, a washer and a new nut.
(2) Tighten the nut according to preloading.
P =1.03 -1.42 Mm - measured with the special tool
(3) Caulk the nut.
(4) Refit the differential housing and the relevant cover.
(5) Refit the half-shafts.
- THIS OPERATION INCLUDES REMOVING THE HALF-SHAFTS AND REPLACING THE SPACER.
PORTER 1.3 16V Differential
DI - 595
Differential removal
Removal
Remove the parts in numerical order, as shown in the figure.
Key
1. Screw
2. Cover
3. Screw
4. Support
5. Spacer
6.Tap roller bearing
7. Nut
8. Washer
9. Pinion connection flange
10. Oil seal
11. Tap roller bearing
12. Spacer
13. Spacer
14. Pinion
Differential PORTER 1.3 16V
DI - 596
18.Spacer
19. Differential housing
21. Screw
22. Crown gear
23. Bevel gear pair support
24. Pin
25. Crown wheel shaft
26. Crown wheels
27. Side pinions
28. Spacer
29.Spacer
30. Plate
31. Gasket
32. Cap
Operations before removal
Position the differential assembly, removed from
the vehicle, on the appropriate work bench.
Specific tooling
020286y Adaptor for attachment to the engine
support
Mark the bearing cap and the differential support,
on the right and left side, respectively.
MARK THEM USING A PUNCH, TO GUARANTEE A COR-
RECT REFITTING
DI - 597
Inspections before removal
Check the following values:
1. Crown gear clearance
Characteristic
Specified value:
0.10 - 0.20 mm
2. Crown gear eccentricity
Characteristic
Limit allowed
0.10 mm
3. Pinion bearing preloading
Measured value with the special tool fitted on the
flange tongue with the oil gasket fitted in its seat
Specific tooling
020335y Magnetic support for dial gauge
Characteristic
Specified value:
0.1 0.2 mm
Main removal operations
1. Remove the hexagon nut, with the following
special tool:
- BEFORE UNDOING THE NUT, UNCAULK IT.
Specific tooling
020212y Flange locking tool
DI - 598
2. Remove the oil seal, with the following special
tool:
Specific tooling
020211y Flange oil seal extractor
3. Remove the bearing, with the following special
tool:
- BE EXTREMELY CAREFUL WITH THE PINION WHICH, AT
THE MOMENT OF BEING DETACHED FROM THE BEAR-
ING, IT CAN JUMP OUT FROM THE SEAT.
Specific tooling
4. Remove the external track of the bearing with
the following special tool:
Specific tooling
020188y Axial hub support and driving pinion
tool series - Front axle bearing and differential
5. Remove the bearing, with the following special
tool:
Specific tooling
020213Y Bearing extractor
6. Mark parts before removing them from the
crown gear. Mark the crown gear and the differ-
ential housing.
DI - 599
Smontaggio
Inspection
Check each section of the following parts, searching for possible damage, wear or excessive clearance.
Replace all the defective parts.
Control pinion and crown gear
1. Gear teeth
2. Pinion grooved section
3. Bearing seat
Side pinion gear and pinion
1. Gear teeth
2. Side pinion gear hub section
3. Side pinion gear toothed section
4. Pin shaft adjustment hole
5. Differential housing of the crown wheel gear
6. Pinion shaft
7. Thrust washer
Differential housing
1. Contact section of the side pinion gear hub (pin-
ion and crown)
2. Pinion contact section
3. Crown gear attachment section
4. Coupling section, bearing side
Bearings
1. Front bearing
2. Rear bearing
3. Side bearing
Make sure that bearings turn freely without jam-
ming or noise.
DI - 600
Differential housing
1. Bearing coupling sections
2. Coupling sections of the bearing rolling external
seat
3. Gasket seat
4. Coupling surface
Coupling flange
1. Oil seal contact section
2. Grooved section
Montaggio
Fitting
Fit the parts in numerical order, as shown in the figure.
Key
1. Screw
2. Cover
3. Screw
DI - 601
4. Support
5. Spacer
7. Nut
8. Washer
9.Pinion connection flange
10. Oil seal
12. Spacer
13. Spacer
14. Pinion
18.Spacer
21. Screw
22. Crown gear
23. Bevel gear pair support
24. Pin
26. Crown wheels
27. Side pinions
28. Spacer
29. Spacer
30. Plate
31. Gasket
32. Cap
Adjustment procedure
1. Adjusting control pinion protrusion
2. Measuring control pinion bearing preloading
Characteristic
Specified value:
102.5 - 141.7 Nm
(When the oil seal is fitted)
3. Differential housing assembly
DI - 602
Characteristic
Specified value:
102.5 - 141.7 Nm
4. Adjusting crown gear clearance and differential clearance in axial direction
Characteristic
Specified value:
0.1 0.2 mm
5. Checking and adjusting the coupling area between the crown gear and the control pinion
6.Checking operations described at points 4 and 5 above
Adjusting control pinion protrusion
1 Fit the following parts, with the following special
tool.
2 Fit the bearing internal rolling fifth wheel in the
differential support.
Specific tooling
3 To determine the size of the shim washer to be
interposed between the pinion and the bearing,
position two opposed flanges, as shown in the fig-
ure. Tighten bolt (5) so that bearings can turn
freely.
4 Position the bearing supports on the differential
unit and tighten the bolts two by two.
5 Measure diameter (d) of the bearing seats.
6 Position pin (7) between the bearing seats and
measure size (Y) with a gauge.
- BE CAREFUL NOT TO TIGHTEN EXCESSIVELY.
Specific tooling
020284y Tool to adjust pinion position
DI - 603
7. Determine the shim washer value with the fol-
lowing formula:
B=Y-3
8. The value of the shim washer to be fitted is ob-
tained calculating the difference of estimated size
B and the size indicated on the pinion head.
Key
1. Size
2. Number of teeth
9 Select the shim washer calculated among all the
available values and fit it by pressure on the pinion
shaft, with the following special tool.
10 Position the shim washer on the control pinion
with the tapered part facing towards the teeth. Fit
the rear bearing by pressure in its seat, with the
following special tool:
Specific tooling
Key
1. Shim washer
AVAILABLE SHIM WASHERS
P/N 132001 Shim washer: 2.50 mm
DI - 604
Bearing preloading measurement
1. Fit a new spacer 1 on the pinion.
2. Fit the pinion in the relevant seat on the differ-
ential support.
3. Fit the front bearing, the oil seal, the flange, the
gasket and the flat washer.
4. Tighten the nut to obtain the pre-set preloading
value.
- APPLY OIL ONTO THE NUT AND TO THE THREADED
PART OF THE CONTROL PINION.
- UPON FITTING, TURN THE PINION IN BOTH DIRECTIONS
MANY TIMES, TO FACILITATE THE BEDDING OF BEAR-
INGS.
5. Pinion preloading check
Value measured with the tool fitted on the flange
shank.
The preloading resistance measured on the bench
is: 10.3 - 14.2 N.
Characteristic
Specification preloading:
1.03 -1.42 Nm
Differential housing fitting
1. Fit the differential housing by following the pro-
cedure indicated below.
Key
1. Differential and side pinion gear
2. Differential and crown wheel
4. Pin
2. When the differential housing is completely assembled, fit the parts listed below:
DI - 605
Crown gear
- CLEAN THE COUPLING SURFACES OF THE CROWN
GEAR AND HOUSING.
MAKE SURE THAT MARKS PUNCHED, IN THE REMOVAL
SEAT, ARE ALIGNED.
Adjusting crown gear clearance and bearing
preloading
1. Fit the differential housing in the support, posi-
tioning the external fifth wheels of the bearings in
the relevant seats.
2. Position shim washers 1 in the relevant seats,
in order to remove the bearing clearance and to fix
clearance between the pinion and the crown gear.
3. Make sure the bearing support marks, punched
in the removal seat, are aligned with the corre-
sponding ones located on the differential support.
4. Check clearance between the pinion and the
crown gear, replace the shim washers so as to ob-
tain a 1.0 mm clearance.
5. Remove the shim washer on the opposed side
of the crown gear and, fit a shim washer with an
oversized value (incremental step of 0.1 mm.) with
an appropriate tool.
DI - 606
6. Remove the tool, refit covers and check clear-
ance between the pinion and the crown gear: 0.1
- 0.2 mm.
7. At the end, tighten the bolts two by two to the
prescribed torque.
Differential bearing support for propeller
shaft 60 - 74 Nm
8. Check total preloading (T) of the bearing (pinion
+differential):
T =(P +0.16) - (P +0.24) N(m {(P +1.6) - (P +
2.4) Kgf-cm}
Where "P" represents the pinion preloading, pre-
viously measured.
The force to exceed the total preloading must be:
(P +1.6) - (P +2.4) N
Section view: shim washer position
Key
1. Adjustment shim washer for crown pinion clearance
DI - 607
2. Cover
3. Protection
Checking and adjusting the teeth contact sur-
face between the crown gear and the pinion
1. Apply minium onto both sides of the gear teeth.
Turn the flange to check the teeth contact surface
between the crown gear and the pinion.
NOTE
TURN THE FLANGE IN BOTH DIRECTIONS, AND CHECK THE CONTACT MARK OF TEETH AT
DIFFERENT POINTS.
Select a flat washer with such a thickness so as to
separate the pinion from the crown gear.
Tip contact/Side contact
Select a flat washer with such a thickness so as to
draw the pinion closer to the crown gear.
Rear contact/Front contact
2. Caulk the nut after checking preloadings and the
pinion-crown gear contact surfaces.
DI - 608
Cover refitting
1. Apply the specified gaskets onto the cover.
2. Refit the cover on the differential housing.
3. Fill the differential with the following oil:
AGIP ROTRA LSX 75W-90 Differential
Characteristic
Capacity
1.1 l
Rear axle differential cover 6.5 - 10.5 Nm
DI - 609
INDEX OF TOPICS
BRAKING SYSTEM BS
Brake
Brake pedal
Brake pipe
Perform the following checks:
1. Hoses and pipes: damage, wear, cracks
2. Hoses: deformation or swelling
3. Pipes: corrosion or swelling
4. Connections: fluid leaks
5. Pipe clamps: tightening
6. Hoses: excessive bending, twisting or traction
KEY:
1. Cracking
2. Wear
3. Twisting
4. Swelling
Empty travel
Stop the engine and push the brake pedal at least
ten times.
Measure pedal clearance A, starting from the neu-
tral position up to the point in which there is resist-
ance.
Characteristic
Pedal clearance A:
2 7 mm
Position wedges under the wheels. Place the gear
in neutral. With the engine at idle speed, releasing
the handbrake lever, push the brake pedal with a
force equal to 490 N (50 kgf). Measure distance
B between the point in which the pedal stops and
the bodywork bottom.
Characteristic
Travel B:
beyond 85 mm
PORTER 1.3 16V Braking system
BS - 611
Removal
Brake pedal
Removal
Remove the parts, following the numerical order illustrated.
KEY:
1. Cotter pin
2. Pin
3. Nut
4. Screw
5. Bracket
6. Pin
7. Brake control pedal
8. Spring
9. Bushing
10. Bushing
Inspection and repair
Inspection and repair
Check the following parts. Replace those defective parts.
Braking system PORTER 1.3 16V
BS - 612
KEY:
1. Bending and twisting
2. Wear
3. Wear
4. Flattening
5. Wear
Installation
Installation
Fit the parts, following the numerical order illustrated.
BS - 613
KEY:
1. Bushing
2. Bushing
3. Spring
4. Brake control pedal
5. Pedal pin
6. Bracket
7. Screw
8. Nut
9. Pin
10. Cotter pin
Adjustment
Pedal travel adjustment
1. Loosen the nut 2 and turn the push rod 3, to
adjust the pedal travel.
2. After adjusting, make sure that the pedal height
matches the specified value and that the tail light
works properly.
BS - 614
Pedal height adjustment
1. Remove the fixing pin of the push rod.
2. Disconnect the stop light switch connector.
Loosen the nut 1 and insert the switch so as to
adjust the pedal height according to the specifica-
tion. Then tighten the nut 1.
3. Loosen the nut 2 and align the u-bolt with the
pin hole. Fit the pin.
4. Adjust the pedal travel and tighten the nut 2.
5. Once adjustment is finished, make sure that the
rear stop light works properly.
Adjusting the reserve travel of the brake pedal
1. Run the engine at idle speed.
2. With the parking brake lever lowered, push the brake pedal exercising 30 kg. force. Then measure
the distance between the brake pedal pushed and the front panel.
SPECIFIED VALUE: NOT LESS THAN 85 MM
SPECIFIED VALUES
Pedal height in mm 132 - 142
Pedal travel in mm 2 - 7
Pedal reserve travel Not less than 85 mm [When the force applied on the pedal is
30 kg]
Brake fluid reservoir
Removal
Removal
Remove the parts, following the numerical order
illustrated.
FIT AND REMOVE THE MAIN RESERVOIR/CYLINDER AS-
SEMBLY FROM THE INSTRUMENT PANEL LOWER SIDE.
BS - 615
KEY:
1. Instrument panel with brake fluid level warning light
2. Heating gate No.1
3. Heating duct No.4
4. Pipe clamp
5. Pipe clamp
6. Bolt
7. Brake fluid reservoir assembly
8. Pipe clamp
9. Pipe clamp
10. Reservoir pipe
11. Hose
12. Pipe No.2 of the reservoir
13. Reservoir cap
14. Reservoir diaphragm
15. Spacer
16. Brake fluid reservoir float
Installation
Installation
Fit the parts, following the numerical order shown in the figure.
BS - 616
KEY:
1. Brake fluid reservoir float
2. Spacer
3. Reservoir diaphragm
4. Reservoir cap
5. Pipe No.2 of the reservoir
6. Hose
7. Reservoir pipe
8. Pipe clamp
9. Pipe clamp
10. Brake fluid reservoir assembly
11. Bolt
12. Pipe clamp
13. Pipe clamp
14. Heating duct No.4
15. Heating gate No. 1
16. Instrument panel with brake fluid level warning light
FIT AND REMOVE THE MAIN RESERVOIR/CYLINDER ASSEMBLY FROM THE INSTRUMENT
PANEL LOWER SIDE.
servofreno
Removal
BS - 617
KEY:
1. Cotter pin
2. Pin
3. Nut
4. Screw
5. Bracket
6. Pipe clamp
7. Brake pipe fitting nut
8. Screw
9. Screw
10. Brake pump assembly with power brake
11. Nut
12. Main cylinder assembly
13. Sealing ring
Brake booster inspection procedure
Power brake hermetic seal check
Start the engine. Stop it after running it for one or two minutes. Push the brake pedal for several times,
applying force necessary during regular braking. If during the second or third time the brake is pushed,
its position lifts gradually, it means that the power brake works properly.
BS - 618
THE INTERVALS BETWEEN THE FIRST AND SECOND TIME THE PEDAL IS PUSHED AS THE
SECOND AND THIRD TIME MUST BE OF FIVE SECONDS.
Power brake operation check
With the engine stopped, push the brake pedal for several times, applying the same force each time it
is pushed. Make sure the brake pedal height does not change each time it is pushed. Start the engine
while pushing the brake pedal, the power brake works properly if the brake pedal is slightly moved.
Checking the power brake hermetic seal with loaded vehicle
With the engine on, push the brake pedal. By pushing and holding down the pedal, shut off the engine.
The power brake works properly if the brake pedal height does not vary, for at least 30 seconds.
Power brake simple check
1. Power brake hermetic seal check. After shutting off the engine, push the brake pedal for several
times. The second, third time the pedal is pushed, the brake pedal position must be higher with respect
to the original position.
2. Power brake operation. Start the engine pushing the brake pedal. Slightly move the pedal during
the engine start-up.
3. Checking the power brake hermetic seal with the vehicle unloaded. After the engine is off, the
brake pedal height must not change.
If the power brake does not comply with requirements proceed with:
Checking the power brake by using a multimeter
4. Power brake multimeter connection.
5. Checking the power brake hermetic seal after the engine is off, vacuum must not vary during 15
seconds.
6. Power brake hermetic seal check. With the vehicle unloaded after the engine is off, the vacuum
drop must remain within 3.3 kPa, during 15 seconds.
7. Power brake operation failure.
A hydraulic pressure of 3.13 Mpa corresponds to 10 Kg of force applied to the pedal;
8. Power brake operation
Power brake multimeter connection
Connect the power brake multimeter as indicated in the figure. Release air from the power brake mul-
timeter. Then perform the checks indicated below.
BS - 619
KEY:
1. Gauge to measure force applied to the pedal
2. Low pressure gauge
3. Pressure gauge
4. Vacuum pump connection hose
Power brake hermetic seal check
Start the engine. Shut the engine off when the low pressure gauge indicates approx. 500 mmHg. Then,
check the power brake air sealing.
Checking the power brake hermetic seal with loaded/unloaded vehicle
With the engine on, push the brake pedal applying 20 kg force. Shut the engine off when the low pres-
sure gauge indicates approx. 500 mmHg. Then, check the power brake air sealing.
Power brake operation failure check
With the engine off, set the low pressure gauge to zero. Under these conditions, check the ratio between
the force applied on the pedal and hydraulic pressure.
Power brake operation check
With the engine on, set the value of the low pressure gauge to approx. 500 mmHg. In this position, push
the brake pedal. Then, check the ratio between the force applied on the pedal and hydraulic pressure.
BS - 620
Brake system
Filling with brake fluid
IF THE BRAKE FLUID COMES INTO CONTACT WITH THE
PAINTED SURFACES OF THE VEHICLE, DRY IT IMMEDI-
ATELY. THEN WASH THE AREA USING UNLEADED PET-
ROL OR A SIMILAR PRODUCT.
KEY:
A =closed
Connection of the plastic pipe to the wheel cyl-
inder bleeding cap
Immerse one plastic pipe end in a brake fluid con-
tainer. Connect the other pipe end to the wheel
cylinder bleeding cap.
Air bleeding
Bleed air following the sequence below:
1. Rear left wheel
2. Rear right wheel
3. LSPV (pressure regulator)
4. Front left wheel
5. Front right wheel
In vehicles fitted with LSPV (pressure regulator)
follow the points indicated below:
Two individuals are required for this
operation. Make sure that the brake
fluid reservoir is always full.
While the first individual loosens the
bleeding cap 1/3 - 1/2 of a turn at a
time, the second individual slightly
pushes the pedal one time and keeps
it pressed.
BS - 621
Then the first individual locks the
bleeding cap and the second one re-
leases the brake pedal.
Repeat the operations described in
previous points until there are no more
air bubbles in the fluid container.
Brake fluid leakage check
Push the brake pedal and check there are no fluid leaks in all the pipe sections.
Front disc brake pad
Removal
Removal
Remove the parts, following the numerical order shown in the figure below.
KEY:
1. Screw
2. Disc brake calliper unit
3. Clip
4. Pad pin
5. Pad unit and thickness
BS - 622
Verifica
- Check that the brake disc is not damaged, that
there are no signs of wear, scores and irregular
wear.
Characteristic
Specified thickness:
16.0 mm
Admissible limit:
15.0 mm
- Check that the brake disc pad is not damaged or
excessively worn.
Characteristic
Specified thickness:
9 mm
Admissible limit:
1 mm
Installation
Installation
BS - 623
KEY:
2. Pad pin
3. Clip
5. Screw
Disc brake calliper assembly for disc brake dust guard 49 59
N.B.
UPON THE BRAKE CALLIPER FITTING, BE CAREFUL NOT
TO PINCH THE PROTECTION COVER OF PISTON A.
Front disc brake
Removal
KEY:
1. Screw
2. Brake calliper unit
3. Cotter pin
4. Castle nut
5. Washer
6. Hub unit and disc
7. Disc brake dust guard
BS - 624
1. Disconnect the hose.
2. Remove the castle nut with the special tool A.
Specific tooling
3. Remove the hub and the disc, with the special
tool B.
Specific tooling
Front disc brake calliper
Removal
Removal
BS - 625
KEY:
1. Spring
2. Pad pin
4. Retention ring
5 Piston
6. Piston cover
7. Piston sealing ring
8. Main bushing
9. Secondary bushing
10. Pin cover
11. Bushing
1. Place a piece of wood between the piston and
the calliper body, as illustrated in the figure, and
remove the piston using compressed air.
N.B.
DURING THIS OPERATION BE CAREFUL THAT THE PIS-
TON DOES NOT COME OUT OF THE SEAT.
BS - 626
Inspection
Check the pads and brake discs. Always replace
parts indicated with *.
PAD THICKNESS AND IRREGULAR
WEAR:
Specified thickness: 9 mm
Limit: 1 mm
DISC THICKNESS AND IRREGULAR
WEAR:
Specified thickness: 16 mm
Limit: 5 mm
Refitting
Assembly
Assemble the parts, following the numerical order illustrated.
KEY:
1. Bushing
2. Pin cover
BS - 627
3. Secondary bushing
4. Main bushing
5. Piston sealing ring
6. Piston cover
7 Piston
8. Retention ring
10. Pad pin
11. Spring
Installation
Installation
KEY:
2. Hub unit and disc
3. Washer
4. Castle nut
5. Cotter pin
BS - 628
7. Screw
* non-reusable parts
Operation following installation
1. Disc eccentricity check
Before checking the disc eccentricity,
make sure that the front wheel bear-
ings are not loose.
Measure the disc eccentricity from the
outside edge.
Characteristic
Limit:
0.15 mm (to 10 mm towards the inside, from the
disc external perimeter).
2. If the disc eccentricity exceeds the limit replace it.
Adjust the brake pedal height.
Rear brake
Removal
KEY:
BS - 629
1. Brake drum
2. Shoe retaining spring
3. Shoe fixing pin
4. Spring
5. Spring
6. Spring
7. Rear brake shoe No. 1
8. Seeger ring
9. Automatic adjustment lever
10. Parking brake shoe strut
11. Seeger ring
12. Washer
13. Automatic adjustment latch
14. Torsion spring
15. Automatic adjustment lever pin
16. Parking brake cable unit
18. Seeger ring
19. Parking brake shoe lever
20. Rear wheel brake cylinder unit
21. Screw
22. Shoe holding plate
23. Wheel cylinder protection cover
24. Wheel brake cylinder piston
25. Cylinder cap
26. Spring
27. Bleeding plug
Inspection
Check the parts, following the numerical order il-
lustrated.
1. Damage and deformation of the shoe.
2. Wear of friction material.
BS - 630
WEAR OF FRICTION MATERIAL
Friction material thickness: 4.0 mm
Maximum limit allowed: 1.0
BRAKE DRUM WEAR
Drum diameter: 200 mm
Maximum limit allowed: 201.5 mm
Check that the brake drum is not damaged, that
there are no signs of wear on the internal surface,
scoring or irregular wear.
KEY:
A. Thickness
B. Gasket
C. Diameter
D. Drum
Installation
Fit the parts, following the numerical order illustrated
BS - 631
KEY:
1. Bleeding plug
2. Spring
3. Cylinder cap
4. Wheel brake cylinder piston
5. Wheel cylinder protection cover
6. Shoe holding plate subassembly
7. Screw
8. Rear wheel brake cylinder unit
9. Parking brake shoe lever
10. Seeger ring
13. Automatic adjustment lever pin
14. Torsion spring
15. Automatic adjustment latch
16. Washer
17. Seeger ring
18. Parking brake shoe strut
19. Automatic adjustment lever
20. Seeger ring
BS - 632
22. Spring
23. Spring
24. Spring
25. Shoe fixing pin
26. Shoe retaining spring
27. Brake drum
1. Apply grease for rubber components at the
points indicated with A and grease for the brake at
the points indicated with B as illustrated.
THE POSITION OF THE SHOE SUPPORT AT THE INPUT
SIDE IS DIFFERENT FROM THAT ONE ON THE OUTPUT
SIDE
BS - 633
2. Apply the recommended product at the end of
the rear axle shaft seat as indicated in the figure
on the right. Then, fit the shoe holding plate on the
rear axle shaft.
Three Bond N.1212 silicone sealant
-
KEY:
1. Section view of the silicon sealant
2. Sealant
3. Apply the piston ring onto the internal edge
3. Apply liquid sealant (recommended product)
onto the fitting area E of the wheel cylinder F on
the shoe holding plate, as indicated.
Three Bond 520 sealing compound
-
4. Apply liquid sealant (recommended product)
onto the fitting area H of the shoe retaining pin G
on the shoe holding plate, as indicated.
Three Bond 520 sealing compound
-
5. Brake adjustment procedure.
Push the brake pedal four or five times (after bleeding the air).
Make sure that the automatic adjustment mechanism works properly.
Adjust the brake pedal height.
Adjust the working travel of the parking brake lever.
Parking brake lever
BS - 634
Removal
KEY:
1. Gearshift lever knob
2. Screw
3. Central tunnel
4. Switch cable
5. Nut
6. Nut
7. Screw
8. Parking brake cable
9. Parking brake lever unit
10. Cover
Installation
Installation
Fit the parts, following the numerical order shown in the figure below.
BS - 635
KEY:
2. Screw
4. Screw
5. Nut
6. Switch cable
7. Cover
8. Central tunnel
9. Screw
10. Gearshift lever knob
Turn set nut A to set the parking brake lever travel,
when the adjustment has been carried out tighten
the lock nut B.
THE PARKING BRAKE LEVER ADJUSTMENT MUST BE
CARRIED OUT WHEN THE CLEARANCE OF THE REAR
BRAKE SHOE COMPLIES WITH SPECIFICATIONS.
BS - 636
Handbrake
Reserve travel
Apply 196 N (20 kgf) of force, slowly pull the hand-
brake lever upwards and count the notches.
Characteristic
Number of notches:
6 10
Parking brake cable
Removal
Operation before removal(pickup model)
Remove the engine inspection compartment cover.
Lift the front left seat.
Remove the rear brake drum. Disconnect the parking brake cable from the rear brake
Removal (Pickup)
KEY:
1. Parking brake cable right guide
2. Parking brake cable left guide
BS - 637
3. Clip
4. Clip
5. Clip
8. Clip
9. Nut
11. Nut
12. Clip
13. Parking brake with brake control cable unit
Operation before removal (van model)
Remove cover A from the engine in-
spection compartment.
Lift the front left seat.
Remove the rear brake drum. Discon-
nect the cable of the rear brake and the
parking brake.
Remove the spare wheel support and
the thermal insulator C to protect the
muffler B.
Removal (Van)
BS - 638
KEY:
3. Clip
4. Clip
5. Clip
6. Clip
9. Clip
10. Nut
11. Parking brake lever
12. Nut
13. Clip
14. Parking brake with control cable
Installation
Fitting (pickup model)
BS - 639
KEY:
1. Parking brake with brake control cable unit
2. Clip
3. Nut
5. Nut
6. Clip
9. Clip
10. Clip
11. Clip
12. Clip
14. Parking brake cable right guide
Fitting (pickup model)
Fit the parts, following the numerical order shown in the figure below.
BS - 640
KEY:
1. Parking brake control cable
2. Clip
3. Nut
4. Parking brake lever
5. Nut
6. Clip
9. Clip
10. Clip
11. Clip
Operation after fitting (pickup)
Adjust the rear brake;
Adjust the parking brake.
Brake controller lspv
LSPV (brake calibrator)
BS - 641
The LSPV (pressure regulator/ brake calibrator) regulates the hydraulic pressure of the proportional
valve according to the weight applied on the vehicle rear axle.
KEY:
1. Side cross-member
2. Rear axle
A = While operating with light load
A' = While operating with regular load
Pm = High hydraulic pressure of the rear main cylinder
Pr = hydraulic pressure of the rear wheel cylinder
BS - 642
Description
KEY:
1. Sealing ring
2. O-ring
3. Cover
4. Cap
5. Retainer
6. Spring
7 Piston
8. Sealing metal gasket
9. O-ring
Pm = Main cylinder hydraulic pressure
Pf = Front brake hydraulic pressure
S = Thrust force of the SPG
A2 = Large diameter section of the piston
Pr = Rear brake hydraulic pressure
F = Piston thrust force
A1 = Small diameter section of the piston
A3 = Small diameter section of the piston
BS - 643
Performance diagram
KEY:
PM = Main cylinder hydraulic pressure
PR = Rear brake hydraulic pressure
W = When the front brake does not work
K = When the SPG sensor is broken
1. PM < PF
The main cylinder pressure PM starts to increase. At this stage, however, there is still clearance between
the main section of the piston A2, and the sealing metal gasket. Therefore, the pressure of the main
cylinder PM is transmitted to the rear brake PR.
PM = PR
2. PM = Pc
When the pressure of the main cylinder PM reaches a PC pressure at the turning point, the piston moves
towards the right of the figure indicated above due to force balancing. Consequently, the piston comes
into contact with the metal gasket.
PM x A1 = F + S
3. PM > PC
If the main cylinder pressure PM increases beyond the PT pressure, the metal gasket is open and
closed. Consequently, the rear brake pressure increases according to the ratio of the piston sectional
area.
1-[A1 /(A2-A3)]
Pr = Pm [1-(A1 /(A2-A3))] + (S+F)/(A2-A3)
4. When the front brake does not work:
BS - 644
Since no pressure is applied to the intermediate diameter section of piston A3, all force applied to the
piston, that is PM (A3 - A1), F and S, acts so that the piston is thrust into the body . Therefore, a clearance
between the large diameter section of piston A2 and the metal gasket remains. Consequently, the
pressure of the main cylinder PM is transmitted to the rear brake.
PM = PR
5. When no more reaction force F is generated towards the piston:
If the spring or the connection system were broken, the braking system works as valve P.
Inspection2
Inspection
1. Preliminary arrangements before the inspection
Park the vehicle on a flat surface and pull the parking brake.
Place weights on the vehicle with an individual sitting at the driving position, load the rear
axle with 400 - 800 kg weights for the Pick up and 450 - 800 kg weights for the Van.
Move the vehicle slowly one meter, forwards and backwards, then return the vehicle to the
original position and pull the parking brake.
Connect a gauge to the front calliper and to the left rear wheel cylinder respectively.
Bleed the air of the gauges.
Check that the LSPV valve is not damaged.
2. Calculation to check front brake pressure:
Calculate pressure at the LSPV turning point according to the weight on the rear axle Wr (kg), with the
following formula:
PICKUP
Rear axle weight: [ 450 kg (MPa): Pc = 21.6 x 10-3 Wr - 6.7
VAN
BS - 645
The value set for checking PF pressure of the front brake must be a higher value than that one obtained
with the following formula: Pressure at the LSPV turning point: Pc +4.9 MPa.
3. Pressure measurement
Push the brake pedal, so that the front brake pressure can reach the value set in the phase "Calculation
to check front brake pressure". At this stage, read the rear brake pressure.
N.B.
IF DURING THE TEST, ONCE THE FRONT BRAKE PRESSURE IS SET, PRESSURE IS
INTERRUPTED ON THE PEDAL, OR THE PEDAL IS RELEASED DURING THE LOWER-
ING TRAVEL, REMOVE THE FOOT FROM THE PEDAL COMPLETELY. THEN REPEAT
THE OPERATION.
SET THE REAR BRAKE PRESSURE VALUE ABOUT TWO SECONDS AFTER THE
FRONT BRAKE PRESSURE IS SET.
4. Pressure test
1. Calculate the reference pressure PR of the rear brake, according to the pressure (PC) at the LSPV
turning point and the checking hydraulic pressure PF of the front brake, calculated at step 2.
PR = 0.1 PF + 0.9 C
2. Calculate the range allowed of the rear brake pressure according to following formula:
Value allowed for the larger side (MPa) : X = 1.98 x 10-3 Wr - 0.19
Value allowed for the smaller side (KPa) : Y= 1.60 x 10-3 - 0.14
3. Determine the rear brake reference pressure according to phases 1 and 2. The rear brake hydraulic
reference pressure must be between (PR + y) and (PR + x).
4. The rear brake pressure measured at step 3 is satisfactory if its value matches the one calculated
above phase. Otherwise, adjust the LSPV.
5. Reference
With a person sitting in the vehicle, place a weight to load the rear axle as it is described:
DO NOT EXCEED 10 KG OF DIFFERENCE BETWEEN RIGHT AND LEFT
Characteristic
Rear axle weight for Pickup
400 5 kg
Rear axle weight for Van
450 5 kg
At this stage, push the brake pedal so that the front brake pressure can turn into 7.85 MPa.
Make sure that the rear brake pressure complies with specifications.
Characteristic
Pickup
2.08 - 2.86 Mpa
Van
1.95 - 2.72 Mpa
BS - 646
Adjustment
1. Measurement calculation of the LSVP connection end movement.
The rear brake pressure changes about 0.13 MPa when the LSVP connection end moves 1 mm up-
wards and downwards. Therefore, calculate the required movement measurement, using the following
formula:
Characteristic
Pressure deviation in MPa (kqf/cm2) =
(Measurement of the LSPV end deviation) mm 0.13 MPa/mm
2. Loosen the nut fixing the LSPV connection to
the axle side. Move the LSPV connection end to
the measurement calculated during phase 1.
BEFORE MOVING THE LSPV CONNECTION, MARK THE
NUT. NEVER SCRATCH OR PUNCH THE SURFACE OF
THE PART.
KEY:
A= the rear brake pressure increases
A= the rear brake pressure decreases
3. Check pressure again. Make sure that LSPV pressure is within the specified field.
Component
BS - 647
LSPV BRAKE CALIBRATOR:
1. Cotter pin
2. LSPV unit (pressure regulator)
3. Pin
4. Cotter pin
5. Washer
6. Bushing
7. Bushing control lever
8. Spring
9. Spring stop
10. Valve control rod
11. Screw
12. Bushing
13. Washer
*: Non-reusable part
Removal
1. Disconnect the brake pipe from the valve body.
2. Remove the valve control screw.
BS - 648
3. Remove the screw fixing the valve bracket.
Removal
1. Remove the cotter pin, then lift the pin.
2. Remove the LSPV with the bracket.
NEVER TRY TO REMOVE THE LSPV
3. Remove the cotter pin.
BS - 649
4. Remove the following parts:
Valve adjustment lever
Washer
Guide bushing
Spring
Spring stop
Valve adjustment bar
5. Remove the guide bushing with a plastic ham-
mer.
Inspection
Check the following parts. Replace those defective
parts.
1. Worn piston
2. Deteriorated plastic parts
3. Damage and distortions
4. Flattening
5. Distortions and damage
BS - 650
Lspv assembly
1. Fit the new guide bushing, with the special tool.
Specific tooling
020196Y Clutch guiding tool
2. Assemble the following parts on the bar:
Spring stop
Spring
Valve adjustment lever
Guide bushing
Washer
3. Fit the new cotter pin
4. Fit the LSPV with the bracket on the control lever
and fit the pin.
BS - 651
5. Fit the cotter pin
Installation
1. Fit the LSPV unit on chassis A.
Afterwards, connect the brake pipe B.
Tighten to the prescribed torque's.
LSPV brake calibrator - Bracket 15 22 Brake
calibrator - Brake pipe 13 18
2. Fix the LSPV articulation lever to the valve
bracket through a belt or other similar object.
WHILE FIXING, MAKE SURE THAT THE PISTON END
COMES INTO CONTACT WITH THE ARTICULATION LEV-
ER COMPLETELY.
Arrange the weight on the rear axle as in the table:
DO NOT EXCEED 10 KG OF DIFFERENCE BETWEEN RIGHT AND LEFT
Characteristic
Rear axle weight for Pickup
363 5 Kg
Rear axle weight for Van
4175 Kg
BS - 652
4. Slowly move the vehicle 1 meter forwards or
backwards. Pull the parking brake.
5. Fit the LSPV articulation end to the bracket, on
the axle side. Tighten the nut to the prescribed tor-
que.
NEVER PUSH THE LSPV END UP AND DOWN WHEN IT IS
ASSEMBLED TO THE BRACKET, ON THE AXLE SIDE.
6. Remove the belt fixing the LSPV articulation lever.
7. Check pressure. If it does not comply with specifications, adjust it.
BS - 653
INDEX OF TOPICS
TRANSMISSION SHAFT TS
This section of the manual comprises information related to the transmission and to the operations
which can be carried out on it.
Components
KEY:
1. Propeller shaft assembly
Inspection on vehicle
Clearance check
Make sure that the universal joint of the propeller
shaft does not show excessive clearance by mov-
ing it in all directions. If any defects are detected,
replace the propeller shaft or the cross.
Noise check
Check that the propeller shaft is not noisy or dam-
aged.
PORTER 1.3 16V Transmission shaft
TS - 655
Removal
Removal
1. Lift the vehicle and hold it by means of safety
stands.
2. Remove the propeller shaft.
- MARK REFERENCES ON THE FORK AND THE JOINT
FLANGE.
- FIT A SUITABLE PLUG TO PREVENT OIL LEAKS.
KEY:
A= Reference marks
B= Plug
Inspection
Inspection
1. Check that the propeller shaft is not damaged
and bent.
2. Check that the cross bearing seat, the sliding
shaft and the cap are not damaged.
Characteristic
Bending limit:
0.5 mm
Transmission shaft PORTER 1.3 16V
TS - 656
3. Check the flange fork and the sleeve fork.
Check that contact surface A of the
flange coupled to the differential pinion
is not damaged.
Check that the sliding surface B of the
oil seal is not damaged or worn.
Check that the grooved section C is not
damaged or worn.
Fit the sleeve fork on the propeller shaft
sliding grooved section. Check there is
no clearance on the grooved section
during the rotation and that the sleeve
can slide freely in the axial direction of
the grooved section.
4. Check universal joint clearance.
Check that there is no clearance on the
cross in the axial direction E.
Check that there is no clearance on the
cross in the perpendicular direction D.
Check that cross rotates regularly.
Installation
Installation
1. Apply oil for gears onto the internal side and on
the external side of the sleeve as indicated in the
figure.
PORTER 1.3 16V Transmission shaft
TS - 657
2. Insert the gear side propeller shaft.
3. Fit the propeller shaft aligning it with the refer-
ence mark A on the differential flange.
4. Fit the fixing bolts with new washers.
5. Tighten the fixing bolts evenly and gradually to
the prescribed torque.
6. Turn the propeller shaft, and check that it is not
forced and does not produce abnormal noises.
Universal joint - Rear differential flange 3954
Transmission shaft PORTER 1.3 16V
TS - 658
INDEX OF TOPICS
STEERING COLUMN SC
Steering arm
Removal
Removal
Remove the parts following the numerical order.
KEY:
1. Nut
2. Elastic washer
3. Bolt
4. Steering arm
5. Bushing
To take out the bushing, use the following series
of special tools with a press, as indicated.
Specific tooling
0.20228y Rear conical tool to replace the dif-
ferential control pinion bearing
Installation
Installation
Fit the parts following the numerical order.
Steering column PORTER 1.3 16V
SC - 660
KEY:
1. Bushing
2. Steering arm
3. Bolt
4. Elastic washer
5. Nut
To fit the bushing, use the series of special tools with a press, as indicated.
Specific tooling
0.20228y Rear conical tool to replace the differential control pinion bearing
Universal joint arm
Components
KEY:
1. Control arm assembly on the stub axle
2. Cotter pin
3. Nut
4. Tie rods
5. Lock nut
6. Plain washer
PORTER 1.3 16V Steering column
SC - 661
7. Control arm on the stub axle
8. Dust guard
9. Gasket
10. Roller bearing
11. Bushing assembly
Removal/Disassembly
1. Turn the steering wheel.
Remove the nut.
Afterwards, take out the arm.
2. Remove the nut on the steering rack side and
with the wheels in straight line motion, take out the
fixing bolt.
3. Disconnect the tie rod end section, using the
following special tool.
Specific tooling
020231Y Extractor for articulated heads
SC - 662
4. Remove the front suspension cross-member.
5. Take out the bushing assembly from the stub
axle control arm.
F: Bushing and washer
6. Take out the roller bearing H, the dust guard G
and the gasket I in the respective sequence, using
the special tools with a press. Follow the same op-
eration on both sides.
N.B.
IF THE BUSHING OR THE WASHER IS DEFECTIVE, RE-
PLACE THEM.
Specific tooling
0.20229y Roller bearing extractor and tool to
replace the oil seal
020230Y Tools for pinion bearing and differen-
tial replacement
SC - 663
Control
Check for possible damage to the bushing assem-
bly and to the bearings.
Installation
1. Fit the bearings with the following special tools
with a press.
First apply lithium based multipurpose grease in
the prescribed quantity inside the bearing.
Specific tooling
020229Y Tools for needle bearing and sealing
rings replacement
tial replacement
Characteristic
Prescribed depth of the bearing (A):
6 6.3 mm
2. Fit the new dust guard gaskets using the follow-
ing special tools.
Before fitting, apply grease onto the sliding surfa-
ces of the dust guard gaskets.
Specific tooling
rings replacement
tial replacement
SC - 664
MAKE SURE TO INSERT THE BUSHING ASSEMBLY IN
THE CORRECT DIRECTION.
Characteristic
Prescribed depth of the dust guard gaskets:
0.1 - 0.7 mm
3. Fit the new dust guard gaskets using the follow-
ing special tools.
Before fitting, apply grease onto the sliding surfa-
ces of the dust guard gaskets.
Specific tooling
rings replacement
tial replacement
4. Apply lithium based multipurpose grease to sec-
tions A indicated in the figure.
5. Insert the bushing assembly in the stub axle
control arm.
MAKE SURE TO INSERT THE BUSHING ASSEMBLY IN
THE CORRECT DIRECTION.
SC - 665
6. Assemble the stub axle control arm with a new
lock nut.
ONCE THE FITTING HAS BEEN COMPLETED, TURN THE
ARM CLOCKWISE AND ANTICLOCKWISE AND MAKE
SURE THAT IT COMES INTO CONTACT WITH THE RELE-
VANT LIMIT SWITCH.
prescribed torque 112 - 137 Nm
7. Fit the front cross-member together with the
control arm assembly.
Cross-member bracket for suspension arm: 98
118 Nm Cross-member - Suspension lower
arm 78.5 98.0
8. Tighten the tie rod head to the prescribed torque
and, afterwards, insert a new locking cotter pin.
Strut bracket body: 39 54 Nm
9. Tighten the unit to the prescribed torque.
Housing on the cross-member for tie rod: 54
69 Nm
10. Front wheel toe-in adjustment and check.
Steering box assembly
SC - 666
Gruppo cremagliera
KEY:
1. Steering joint cover
2. Bolt
3. Reinforcement bar support
4. Bolt
5. Bolt
6. Steering box
7. Dust guard
8. Bushing
9. Intermediate shaft
10. Elastic coupling
11. Steering box flange
SC - 667
1. Lift the front part of the vehicle with the jack.
2. Remove the steering housing cover aligning the
special section A of the plate with the pinion flange.
Removal
Remove the parts following the numerical order
KEY:
1. Hexagonal ring nut
2. Spring cap
3. Spring
4. Rack guide
5. Ring
6. Clamp
7. Steering rack bellows
8. Clip and Circlip
9. Nut
10. Bracket
11. Ring
SC - 668
12. Clamp
13. Bellows
14. Steering box cover
15. Gasket
16. Circlip
17. Steering pinion
18. Rack
19. Dust guard
20. Oil seal
21. Circlip
22. Ball bearing
1. Position the steering guide box in a vice using
copper or aluminium jaws.
2. Remove the hexagon nut with a 39 mm Allen
key.
3. Remove the rack guide spring cap with a 17 mm
Allen key.
SC - 669
4. To avoid damaging toothed surfaces, remove
the locking nut acting on the working section with
a 17 mm key. The working section is provided by
the rack end, as shown in the figure.
5. Remove the circlip with pliers to expand circlips.
6. Move the rack rotating the pinion until the rack
teeth are disengaged from those of the pinion.
7. Take out the pinion using a punch (with a diam-
eter of approx. 12 mm), as shown in the figure.
8. Remove the circlip with pliers to expand circlips.
9. Take out the bearing very gently with a punch,
as shown in the figure.
Control
Check the following parts and replace those which are defective.
SC - 670
KEY:
1. Toothed surfaces worn or damaged
2. Bushing worn or damaged
3. Toothed surfaces worn or damaged
4. Damage, crack
5. Wear
6. O-ring
7. Deterioration
8. Wear or damage
9. Damage, crack
Refitting
Check the following parts and replace those which are defective.
SC - 671
KEY:
1. Ball bearing
2. Circlip
3. Oil seal
4. Dust guard
5. Rack
6. Steering pinion
7. Circlip
8. Gasket
9. Steering box cover
10. Bellows
11. Clamp
12. Ring
13. Bracket
14. Nut
15. Clip and Circlip
16. Bellows
17. Clamp
18. Ring
19. Rack guide
20. Spring
SC - 672
21. Spring cap
22. Hexagonal ring nut
Steering box assembly
Fitting
1. Apply EP grease (high resistance) at the points
indicated in the figure in the prescribed quantity.
Roller bearing section A: 0.2 - 0.4 gr.
Sintered bushing section B: 0.2 - 0.4 gr.
2. Fit the ball bearing with the special tool.
Specific tooling
3. Fill the ball bearing with EP grease in the pre-
scribed quantity.
4. Fit the circlip with pliers to expand circlips.
5. Fit the oil seal with the special tool.
Specific tooling
SC - 673
6. When fitting the oil seal, cover the whole edge
of the oil seal with MP grease.
7. Apply EP grease onto toothed surfaces and on
the rack shaft in the prescribed quantity.
Prescribed quantity
Rack end C: minimum quantity
Toothed surface D: 4 gr.
Shaft E: 1 gr.
8. Apply EP grease onto the rack guide F fitting
hole in the prescribed quantity.
Prescribed quantity of grease: 2 - 4 gr.
9. Insert rack G in the relevant seat H in the posi-
tion indicated in the figure.
10. Position the pinion with a punch.
SC - 674
11. Fit the circlip with pliers to expand circlips.
Assembly procedure
Assembly procedure of the rack and the steer-
ing pinion
1. Position the rack in the relevant seat with the
pinion flange as indicated.
2. After engaging the rack and the pinion, make
sure that the pinion and the rack assume the indi-
cated position.
3. With a plastic cap, protect the threaded section
of the rack so as to avoid damaging it during as-
sembly.
SC - 675
4. Tighten bellows A.
5. Position the rack end following the perspective
6. Tighten the lock nut with a 17 mm wrench.
7. With the rack in a neutral position, fit the spring
cap to the prescribed torque. Turn the rack approx.
10 - 20 times up to its bedding. Loosen the spring
cap and take the rack to a neutral position. After-
wards, restore the spring cap to a 7 Nm torque with
a 17 mm key so as to form an angle of 50 5.
Rack spring cap 7
8. Fit the hexagon nut with a 39 mm Allen key.
Rack guide protection lock nut - Steering rack
housing 34 44
Steering pinion preloading
Check the steering pinion preloading.
Characteristic
Prescribed value:
0.5 - 1.1 Nm
SC - 676
Installazione complessivo
Fit the parts, following the numerical order of the figure shown below.
KEY:
1. Steering box flange
2. Elastic coupling
3. Intermediate shaft
4. Bushing
5. Dust guard
6. Steering assembly
7. Bolt
8. Bolt
9. Reinforcement bar support
10. Bolt
11. Guard
Steering column
SC - 677
Removal
Key switch cylinder removal
1. Insert the ignition key and turn it to the "IGN"
position.
2. Acting by means of the upper hole, keep the lock
section in position and take out the key switch cyl-
inder from the guide column upper support brack-
et.
KEY:
1. Steering wheel
2. Guide column protection
3. Light switch lever unit
5. Bolt
6. Steering column
7. Washer
8. Ring
9. Universal joint
SC - 678
Installation
KEY:
1. Ring
2. Washer
3.Universal joint
4. Steering column
5. Bolt
7. Light switch lever unit
8. Guide column protection
9. Steering wheel
Installation
1. Apply MP grease onto the PP points indicated.
SC - 679
2. Position the front wheels in straight line motion
and fit the universal joint in the indicated position.
KEY:
A =Universal joint;
B =Intermediate shaft
3. Fit the guide column so that the milling on the
grooved section is aligned with the fixing bolt hole.
KEY:
C =Specific section;
D =Fixing bolt hole.
4. Tighten bolts E and F temporarily, as indicated
in the figure, then fit the steering wheel provision-
ally.
5. Turn the steering wheel two or three times to-
wards the right and left, afterwards, straighten the
front wheels.
6. Tighten bolts E and F to the prescribed torque.
7. Remove the steering wheel fitted provisionally.
8. Fit the steering wheel so that the groove on the
rear section of the steering wheel is aligned with
the turn indicator switch cam.
SC - 680
9. Apply grease at the indicated point G.
Tie-rods
Removal
Remove the parts, following the numerical order of
the figure shown below.
1. Cotter pin
2. Nut
3. Cotter pin
4. Nut
5. Tie rods
6. Arm head
7. Dust-protection ring
9. Arm head
10. Ring
11. Dust guard
1. Lift the vehicle with a jack.
2. Remove the tie rod assembly using the special
tool.
Specific tooling
020231Y Extractor for articulated heads
SC - 681
Control
Check the following parts and replace the defec-
tive ones.
1. Breaking and deterioration
2. Damage and bending
3. Breaking and deterioration
Installation
Remove the parts, following the numerical order of
the figure shown below.
1. Dust guard
2. Ring
3. Arm head
4. Dust guard
5. Ring
6. Arm head
7. Tie rods
8. Nut
9. Cotter pin
10. Nut
11. Cotter pin
1. Apply the prescribed quantity of lithium based
multipurpose grease at the points specified in the
figure.
MAKE SURE THAT THERE IS NO GREASE ON THE CONI-
CAL SECTION OR THE THREADED SECTION.
Characteristic
Prescribed quantity of grease
3 cm
Arm head
MAKE SURE THAT THE ARM HEAD WITH ANTICLOCKWISE THREAD IS ON THE CENTRAL ARM
SIDE OF THE RIGHT TIE ROD ASSEMBLY AND ON THE ARTICULATION SIDE OF THE LEFT TIE
ROD ASSEMBLY.
SC - 682
2. The distance between the arms of the head
must correspond to the figure specification. Tight-
en the lock nut temporarily (after performing the
toe-in test, tighten the lock nuts firmly).
CHECKING AFTER FITTING THE ARM HEADS
1. Check toe-in
TOE-IN
B-A (one passenger) 2.0 +1.5 - 1.0
B-A (unloaded vehicle) 1.5 +1.5 - 1.0
Alignment
Toe-in
1. Check the tyre pressure. Position the vehicle on
a car lift. Swing front and rear sections of the ve-
hicle up and down so that the front and rear sus-
pensions can settle in their regular condition.
2. Check for possible signs of wear or eccentricity of tyres or excessive clearance in axial direction
detected on wheels.
3. Make sure that no front suspension mechanism and steering shows excessive clearance.
4. Measure the distance between the marks on the front side of each front wheel. Determine the toe-
in value calculating the difference.
TOE-IN
SC - 683
5. If the toe-in value is not within the prescribed
specifications, loosen the lock nuts of the arm
head. Perform adjustment on tie rods C.
N.B.
ADJUSTMENT SHOULD BE SO THAT THE LENGTH OF
THE RIGHT SIDE CABLE AND THE LEFT SIDE CABLE ARE
IDENTICAL.
6. Take the turning radius gauge to 0 degrees.
Straighten the wheels and check the steering an-
gle as follows:
a. Turn the steering all the way towards the right
and left respectively.
Read the turning radius gauge scale on the right
and left sides.
MAKE SURE THAT WHEELS DO NOT INTERFERE WITH
THE BODY DURING ROTATION.
b. Check the tyre steering angles when the steering wheel is turned all the way towards the right and
left respectively.
IF THE LEFT TIE ROD LENGTH IS INCREASED BY TWO TURNS, DECREASE THE RIGHT TIE
ROD LENGTH BY TWO TURNS TO MAKE SURE THAT THE TOE-IN IS THE SAME .
STEERING ANGLES
Inside: 36
Outside: 34.8
Tolerance between right and left sides: 3
Front wheel alignment check
The suspension is of reinforced type, the components have a significant rigidity and the distance be-
tween lower and upper support points is prominent.
The front wheel alignment remains unchanged, unless the vehicle suffers sudden accidents.
However, if the front wheels are misaligned due to an abnormal tyre wear, an incorrect driving or due
to other causes, restore correct alignment.
SC - 684
PICK UP FRONT WHEEL ALIGNMENT
Tie rod 1 23' +40'-50'
Caster angle 313' 1
Steering angle 149' 1
VAN FRONT WHEEL ALIGNMENT
Camber angle 1 +40'-50'
Caster angle 302' 1
Kingpin inclination angle 1125' 1
TOE-IN
Toe-in with a passenger 2.0 +1.5-1.0
Toe-in with unloaded vehicle 1.5 +1.51.0
BEFORE MEASURING THE FRONT WHEEL ALIGNMENT, CHECK THE REGULAR VEHICLE
HEIGHT AS IN THE CASE OF TOE-IN MEASUREMENT. BESIDES, MAKE SURE THAT NO PART
OF THE VEHICLE IS LOOSE.
2. Place a turning radius gauge on a flat surface
so as to keep the vehicle levelness. Perform meas-
urement slowly.
3. Before measuring, swing the front and rear part of the vehicle up and down so that front and rear
suspensions settle in their regular condition.
4. Perform the measurement with brakes locked.
Steering wheel
Controlli
Steering wheel clearance
Position the vehicle with the wheels straight.
Check steering wheel clearance "A" turning it
slightly with the fingers.
Specified value: less than 30 mm
SC - 685
Move the steering wheel in axial direction with re-
spect to the guide column. Check if the steering
wheel shows excessive clearance or loosening.
N.B.
IF THE STEERING WHEEL SHOWS EXCESSIVE CLEAR-
ANCE OR LOOSENING,PROBABLY THE STEERING BOX
OR THE JOINTS ARE WORN, OR THE SUPPORTING
BRACKET HAS BEEN LOOSENED.
Removal
KEY:
1. Steering wheel padding
2. Nut
3. Washer
4. Steering wheel
5. Screw
6. Horn plate
7. Horn ring
BEFORE REMOVAL, DISCONNECT THE BATTERY TERMINAL CABLE.
Installation
KEY:
1. Horn ring
2. Horn plate
3. Screw
4. Steering wheel
5. Washer
SC - 686
6. Nut
7. Steering wheel padding
Wheel alignment
Toe-in measurement
1. Shake the vehicle manually so as to level its
height.
2. Move the vehicle approx. 5 meters forwards so
that front wheels are not steered.
- DURING MEASUREMENT, DO NOT MOVE THE VEHICLE
BACKWARDS.
3. Put the gauge pointer at the centre of the front wheel tread.
4. Mark a reference at the centre of the tread of each of the front wheel tyres, on the rear side. Measure
the distance between the two marks (Size A) in the figure.
5. Move the vehicle slowly, pushing it until the wheels are turned 180.
6. Measure the distance (Size B) between the two references marked in the previous phase. Perform
this measurement from the vehicle front side. Calculate the toe-in value A-B.
TOE-IN
Toe-in adjustment
1. Loosen the lock nuts of the tie rod heads.
2. Adjust toe-in by turning the tie rod heads.
- BE CAREFUL NOT TO KINK THE COVER DURING THE
ADJUSTMENT.
- WHILE ADJUSTING TOE-IN, RIGHT AND LEFT TIE-RODS
MUST HAVE THE SAME SIZE.
- LENGTH (A) INDICATED IN THE FIGURE ON THE RIGHT
MUST BE THE SAME ON THE RIGHT AND LEFT SIDES. (IF
THE LENGTH ON THE LEFT SIDE IS DIFFERENT FROM
THE RIGHT SIDE, THERE IS A DIFFERENCE IN THE
WHEEL STEERING ANGLE, BETWEEN THE RIGHT AND
LEFT SIDES).
SC - 687
SC - 688
INDEX OF TOPICS
SUSPENSIONS SS
Front
Axle and front suspension
This section of the manual describes how to inspect, remove and fit the axle and the front suspension.
KEY:
1. Cotter pin
2. Castle nut and flat washer
3. Brake calliper assembly and disc
5. Cotter pin
6. Castle nut
7. Tie rod assembly
8. Nut and bolt
9. Suspension lower arm assembly
10. Steering articulation
11. T oil seal
12. T oil seal
14. Collar
16. Wheel shaft
17. Front shock absorber
Suspensions PORTER 1.3 16V
SS - 690
Shock-absorbers removal
Assembly
1. Insert the dust guard and the elastic buffer in the
shock absorber stem.
2. Compress the spring, using the following tool:
Specific tooling
3. Fit the spring seat upper cap B and the bushing
A.
- APPLY 0.5 GR OR MORE MT GREASE ON THE UPPER
SURFACE OF BUSHING A.
4. Fit the front suspension support C
5. Temporarily tighten the nut. (Use a new nut).
- DURING THE ASSEMBLY, REMEMBER TO ALIGN THE
PART SEPARATED FROM THE FRONT SUSPENSION
SUPPORT C WITH THAT OF THE SHOCK ABSORBER
STEM D.
6. Lock the front suspension support in a vice.
Tighten the suspension support nut to the shock
absorber stem.
Shock absorber - Front suspension support
49.0 69
PORTER 1.3 16V Suspensions
SS - 691
7. Fit the support dust guard.
8. Align the spring end with the concave section of
the upper seat F and lower seat G. Remove tool
H.
Installation
Fit the suspension support. (Use new nuts)
Front suspension support for chassis 35 - 44 Nm
Steering articulation fitting
1. Fit the steering articulation on the lower support
of the shock absorber.
2. Fit the new bolts and screws in the relevant
seats and tighten them temporarily.
3. Connect the brake hose to the calliper.
4. Fit the clip locking the pipes on the shock ab-
sorber.
5. Bleed the air completely.
6. Move the vehicle, without load, upwards and
downwards, so that the suspension settles.
7. Tighten the following:
Bolt and nut (Shock absorber for steering articu-
lation)
SS - 692
COMPONENTS:
1. Support dust guard
2. Self-locking nut
3. Front suspension support
4. Bushing
5. Front spring upper seat
6. Front spring buffer
7. Shock absorber dust guard
8. Spiral spring
9. Front shock absorber
10. Bolt
11. Retention plate
Removal
1. Lift the vehicle with the jack
2. Remove the front wheel.
N.B.
- MAKE SURE THAT THE JACK IS PLACED CORRECTLY,
MATCHING THE LIFTING POINTS.
SS - 693
3. Remove the seat in order to reach the upper
seat of the front shock absorber.
4. Remove the shock absorber pipe fixing bracket.
5. Detach the brake hose from the calliper.
6. Shock absorber removal.
- Remove the fixing nuts.
- Leave the bolts fitted in their places.
- Remove the three suspension fixing nuts.
- Remove the steering articulation fixing bolts.
- Take out the shock absorber.
Removal
- Compress the spring using the following tool.
Specific tooling
Spring removal
1. Tighten the front suspension support in a vice.
2.Remove the dust guard of the support
3.Loosen the nut.
- NEVER HIT THE NUT.
SS - 694
4. Remove the support of the front suspension A.
5.Remove the bushing and the upper seat of the
front spring B.
6.Remove the spiral spring, dust guard and rubber
buffer from the shock absorber.
Check
Check the following parts:
A =Damaged rubber part
B =Endless screw bushing
C =Damage or twisting
D =Wear
E =Twisting and breaking
F =Flattening
G =Oil leak
Shock absorber operation check
1. While pressing the shock absorber stem, check
that compression is uniform along the whole travel,
and that there is no abnormal resistance or noise.
2. Check for the same conditions with the stem
extended. Check that it returns at a constant speed
from the beginning to the end.
3. If the shock absorber operation fails, replace it.
- DISCHARGE ALL THE GAS BEFORE DISPOSING OF THE
SHOCK ABSORBER.
Front arms removal
Suspension lower arm
SS - 695
COMPONENTS:
1. Throttle cable locking bolt
2. Speedometer cable tightening screw
3. Nut and bolt
4. Stud bolt (not provided as a spare part)
5. Screw
6. Lock nut
7. Hexagonal bolt
8. Suspension lower arm
9. Lock nut
10. Flat washer
11. Strut buffer
12. Strut support
13. Strut buffer
14. Lower ball joint dust guard
SS - 696
Removal
N.B.
3. Removal of the suspension lower arm assem-
bly.
Remove the bolt and the fixing nut of
the steering articulation.
Remove the suspension lower arm
from the steering articulation.
Remove the suspension lower arm by
removing the cross-member bolt.
Remove the suspension lower arm tak-
ing out the nut from the strut support.
Remove the suspension lower arm
from the vehicle.
4. Remove the strut support after taking out the
four hexagonal bolts.
Check
Check the components and replace them if nec-
essary
A. Deterioration
B. Torsion and damage
SS - 697
C. Twisting and breaking
Installation
1 Insert the strut buffer on the suspension lower
arm.
2. Temporarily fit the strut support on the body-
work.
3. Fit the strut buffer and the plain washer on the
strut support and temporarily tighten the locking
bolt.
4. Fit the strut support with the four hexagonal-
head bolts.
Strut bracket body 39 54
5. Apply the ball-and-socket joint in the steering
articulation and insert the bolt.
6. Temporarily fit the screw and the lock nut.
- MAKE SURE THAT NEITHER GREASE NOR OIL OR ANY
OTHER SUBSTANCES COVER THE SCREW AND THE NUT
FASTENING THE BALL-AND-SOCKET JOINT.
7. Fit the front wheel.
8. Lower the vehicle. Move the unloaded vehicle
up and down so that the suspension settles. With
the vehicle unloaded (lower arm in horizontal po-
sition). Follow the operations below:
9. Tighten:
- Bolt and nut
- Lock nut
- Bolt and nut
10. Adjustment and check of the front wheel align-
ment.
Cross-member - Suspension lower arm 78.5
98.0
SS - 698
Front hubs removal
Removal
N.B.
5. Disc assembly removal
Remove the cotter pin
Remove the castle nut using the fol-
lowing tool:
6. Remove the disc brake assembly using the fol-
lowing tool:
Specific tooling
0.20222y Front hub and drum extractor
3. Disconnect the brake hose from the calliper.
4. Remove the calliper assembly by unscrewing
the two bolts.
N.B.
- COVER THE BRAKE HOSE CONNECTION WITH A CLOTH
TO KEEP DUST FROM ENTERING.
SS - 699
7. Remove the disc brake dust guard
8. Remove the tie rod head, using the following
tool:
Specific tooling
9. Remove the articulation of the steering by un-
screwing bolts A and B
Installation
1. Install the steering articulation.
SS - 700
2. Fit the tie rod on the articulation.
- ALIGN THE CASTLE NUT RECESS WITH THE HOLE.
Tie rod head - Articulated arm 39 54
3. Fit a new cotter pin on the castle nut.
4. Fit the brake disc dust guard.
Brake disc dust guard - Wheel hub joint 39.3
53.9
5. Fit the hub and the disc assembly, and tighten
the castle nut, using the following tool:
- ALIGN THE CASTLE NUT RECESS WITH THE HOLE.
Specific tooling
Castle nut - Front axle hub 177.0 216.0
6. Fit a new cotter pin on the castle nut.
7. Install the calliper assembly with two bolts.
8. Connect the brake hose to the calliper.
- BE CAREFUL NOT TO DAMAGE THE COVER.
Disc brake calliper - Disc brake dust guard 49
59
SS - 701
Inspection
Check the following parts. Replace any faulty
parts.
1. Front axle bearing replacement
With a press, remove the wheel shaft
from the steering articulation.
Move the collar, as shown in the figure.
Remove the bearing by pushing the
collar.
2. Front axle bearing installation
Place the internal radial ball bearing
using the following tool:
N.B.
- MAKE SURE THAT THE BEARING IS IN CONTACT WITH
THE STOP SECTION OF THE STEERING ARTICULATION.
Specific tooling
SS - 702
Place the external radial ball bearing
N.B.
- MAKE SURE THAT THE BEARING IS IN CONTACT WITH
THE STOP SECTION OF THE STEERING ARTICULATION.
Specific tooling
Place the internal and external oil seal,
Specific tooling
020223y Extractor and changer for front sus-
pension arm bushing
3. Place the wheel shaft in the articulation
Use the following tool:
Specific tooling
020224y Connecting rod bushing extractor and
changer
Verifiche e regolazioni
Preliminary checks before the wheel alignment
check
1. Tyre wear check
2. Correct tyre pressure control
3. Checking bolt tightening of affected parts
SS - 703
4. Checking excessive clearance of the affected
parts.
Lift the vehicle with the jack. Push and
pull alternatively the lower and upper
part of each tyre. Make sure that these
parts do not have excessive clearance.
If one of the tyres has an excessive
clearance, check again with the brake
control pedal lowered.
If there is excessive clearance, then the front
wheel bearing is loose.
If there is still excessive clearance, then the steer-
ing articulation or suspension section is loose.
Spring
Inspection
visually inspect all the springs and check that there
are no signs of damage or cracking.
Attachments and joints
Check the attachments for correct
tightness and signs of damage.
Check that the joints are not noisy.
KEY:
1. Spiral spring
2. Shock absorber
3. Connection bar
4. Suspension lower arm
Shock Absorbers
Inspection
Visually inspect all the shock absorbers and check that there are no signs of deterioration and fluid
leaks.
SS - 704
Operation check
Push the rear part of the vehicle with downward force in order to check the damping capacity of the
shock absorbers.
In the case that the wheel bearing is loose, check
the clearance in the axial direction, using the fol-
lowing tool and the micrometer.
Specific tooling
Characteristic
Front wheel bearings
Specified value
Maximum limit: Do not exceed 0.05 mm
PICK UP FRONT WHEEL ALIGNMENT
Camber angle 123' +40'-50'
Caster angle 313' 1
Toe-in 1 passenger: 2.0+1.5-1.0
Unloaded vehicle: 1.5+1.5-1.0
Steering angle Inside: 36+0-3
Outside: 34.8+0-3
VAN FRONT WHEEL ALIGNMENT
Camber angle 1 +40'-50'
Caster angle 302' 1
Toe-in 1 passenger: 2.0+1.5-1.0
Unloaded vehicle: 1.5+1.5-1.0
Steering angle Inside: 36+0-3
Outside: 34.8+0-3
Turning radius gauge setting
Set the turning radius gauge to point
zero. Lock the indicator.
Place the vehicle so that the wheel/
flooring surface is aligned with the cen-
tre of the turning radius indicator.
- CARRY OUT THE CHECK ON LEVEL GROUND.
- IF A PORTABLE TURNING RADIUS GAUGE IS USED,
PLACE A PLATE WITH THE SAME THICKNESS AS THAT
OF THE INDICATOR UNDER THE REAR WHEEL IN ORDER
TO KEEP THE VEHICLE LEVEL.
- MAKE SURE THAT THE FRONT WHEELS ARE NOT
STEERED.
- KEEP THE VEHICLE UNLOADED. MAKE SURE THAT THE
BRAKE PEDAL IS ENGAGED, USING A BRAKE PEDAL
THRUSTING DEVICE, SO THAT THE VEHICLE DOES NOT
MOVE DURING CHECK.
SS - 705
- REMOVE THE STOP LIGHT FUSE SO THAT IT DOES NOT
REMAIN ON.
External side wheel steering angle check
1. Measure the wheel steering angle with an internal side turning radius indicator. Specified value:
2. If there is a difference between the right and left side of the wheel steering angle, correct the steering
angle
Characteristic
External side B
34.8+0-3
Internal side C
36+0-3
KEY:
A =Front
B =External side
C =Internal side
Wheel steering angle correction
1. Loosen the lock nuts of the tie rod heads.
2. Length (a), indicated in the figure at the right,
should be the same between the right and left
sides.
- BE CAREFUL NOT TO KINK THE CAP DURING THIS OP-
ERATION.
- MAKE SURE THAT THE TIE RODS ON BOTH LEFT AND
RIGHT SIDE ARE THE SAME SIZE.
Checking the camber, caster and kingpin an-
gles
1. In the case of aluminium wheels, carry out the
measurement by using the CCK (camber, caster,
kingpin inclination) gauge.
- THE TOE-IN CHECK (CCK-IN) EQUIPMENT CAN BE USED
ALSO ON STEEL WHEELS.
SS - 706
2. Fitting procedure of the equipment to check toe-
in, camber, caster and kingpin.
KEY:
A =CCK pitch compensator
B =CCK pitch compensator
C =Zero mechanical line
D =Fitting plate
E =Compensator dial
Lift the vehicle with the jack.
Before fitting the CCK gauge on the
wheel, place the pitch compensator on
the zero mechanical line, F turning the
compensator dial.
SS - 707
Fix the equipment to check toe-in, firm-
ly hooking the four stop pins to the
wheel rims.
- TO AVOID SCRATCHING THE WHEEL RIMS, APPLY A
TAPE ON THE RIMS MATCHING THE INSERTION POINTS
OF THE COMPENSATOR PINS.
Place the camber, caster and kingpin
gauge on the equipment fitting plate.
Now, align the lines of the gauge and
the equipment.
Turn the wheel so that the air bubble in
the gauge reaches the central position.
In this position, turn the gauge caster
set screw, so as to align the caster air
bubble with the zero position.
Turn the wheel by 180, so as to invert
the gauge. Align the lines set on the
gauge and on the compensator. Then,
turn the wheel so that the air bubble in
the gauge reaches the central position.
SS - 708
Set the caster value read from the
gauge. Turn the compensator dial G so
as to align it at the half of the set caster
value.
- PAY ATTENTION NOT TO TAMPER WITH THE GAUGE
CASTER SET SCREW.
Repeat the operations described at the two previous points. Make sure that the caster gauge
air bubble sets the same value when the wheel is turned by 180 degrees in a regular or
inverted direction.
Lower the wheel on the turning radius indicator. Manually shake the vehicle upwards and
downwards so as to stabilise suspension.
4. Camber check
Make sure that the front wheels are not
steered.
Align the air bubble H with the central
position
Set the camber value I read from the
gauge
Characteristic
Specified value:
1 +40' - 50'
5. Check the caster and kingpin inclination angle
Turn the steering wheel to the right, so that the right front wheel reaches the point in which
the steering angle gauge L registers 20 degrees.
Turn both caster and kingpin set screws so as to align the respective air bubble with the
zero point.
Turn the steering wheel to the left, so that the right front wheel reaches the point in which
the steering angle gauge L registers 20 degrees.
Set the values of the caster angle M and of the kingpin read from the gauge.
Characteristic
Specified value:
Caster: Pickup 313' 1, Van 302' 1
Kingpin inclination angle: Pickup 1049' 1 Van 1125' 1
SS - 709
Following the right wheel procedure, check also the left wheel. However, the steering wheel
steering direction shall be inverted.
Rear
Axle and rear suspension
This manual section describes how to check, remove and fit the axle and rear suspension.
Wheel hub
COMPONENTS
1. Drum
2.Nut
3. Rear axle shaft
4. Internal snap ring
5. Bearing
6.Spacer
7.Shoe holding plate
SS - 710
8. Oil seal
Removal
1. Lift the vehicle with the jack.
N.B.
2.Drain the differential oil.
3. Remove the rear wheel.
4. Loosen the parking brake set screw.
5. Disconnect the brake transmission from the
splitter and from the chassis.
6. Disconnect the brake hose fitting from the wheel
cylinder.
7. Remove the brake drum.
8. Remove the four nuts fixing the shoe holding
plate.
9. Remove the rear axle shaft with the shoe hold-
ing plate, using the special tool:
Specific tooling
SS - 711
10. Remove the oil seal, using the special tool:
Specific tooling
020200Y Extractor
11. Rear axle bearing removal
With a disc grinder, grind the stop
bushing of the bearing, leaving a re-
maining thickness of about 1 mm.
Cut the stop bushing A with a chisel B
and remove it from the axle shaft.
Remove the bearing, using the follow-
ing special tool:
Specific tooling
020227y Rear wheel bearing extractor
SS - 712
Check
Check the following parts:
1. Rear axle shafts, especially:
A Wear, damage or eccentricity
B Oil seal contact section
C Grooved profile
Characteristic
Limit allowed:
Flange: 0.05 mm
Axle shaft: 0.80 mm
2. Bearing A worn or damaged
3. Oil seal contact section in the rear bridge hous-
ing.
Installation
1. Insert the shoe holding plate with spacer A, with
the special tool and press insert the axle shaft
bearing.
Specific tooling
KEY:
A Spacer
B Shoe holding plate
C Bearing
SS - 713
Heat a new bearing stop bushing E in an oil bath
at approx. 150, and with the aid of the special tool,
insert it quickly until it stops against the bearing.
Specific tooling
Quickly fit the bearing sealing ring on the shaft,
using a press together with the special tool.
- MAKE SURE THERE IS NEITHER GREASE NOR OIL ON
THE REAR AXLE SHAFT AND THE SEALING RING.
Specific tooling
2. Apply MP grease on the oil seal edge.
3. Fit the oil seal, using the following special tool.
Specific tooling
020201y Gear bearing fitting punch
4. Apply silicone sealant at the housing end of the
rear axle shaft. Apply sealant uniformly, as shown
in the figure, to cover the rear axle shaft coupling
surfaces.
N.B.
APPLY THE SEALANT WITHOUT INTERRUPTIONS.
AFTER APPLYING THE PRODUCT, CARRY OUT THE OP-
ERATIONS IMMEDIATELY.
Three Bond N.1212 silicone sealant
-
Key
1. Silicone sealant section view
2. Silicone sealant
3. From the base of the bearing, fit an elastic gasket on the internal edge
SS - 714
5. Fit the rear axle shaft together with the shoe
holding plate, using the following special tool.
Specific tooling
6. Fasten the shoe holding plate with four nuts.
Shoe holding plate - Rear axle shaft housing
63.7 70.4
7. Insert the brake hose fitting nut.
8. Fit the hand brake cable end.
9. Fit the hand brake cable adjustment nut.
11. Adjust the brake shoe clearance.
12. Restore the oil level in the differential.
13. Fit the wheel.
14. Lower the vehicle.
Brake pipe joint - Brake cylinder 10 12
SS - 715
Balestra
COMPONENTS
1) Nut, 2) Spring washer, 3) U-bolt,4) Rear rubber buffer, 5) Flexible shoe (for vans), 6) Nut, 7) Spring
washer 8) Nut, 9) Spring washer, 10) Rear shackle, 11) Rear shackle, 12) Bushing, 13) Nut, 14) Upper
spring pin, 15) Spring washer, 16) Leaf spring with bushing, 17) Flexible shoe stop, 18) Flexible shoe
(for vans).
Removal
N.B.
2. Remove the rear wheel.
3. Disconnect the +and - battery leads.
4. Remove the battery housing by undoing the
three bolts/clips and a ground bolt (only for vans).
SS - 716
5. Remove the U-bolt by undoing the four nuts.
6. Remove the rear rubber buffer support and the
flexible shoe of the leaf spring.
7.Remove the shackle of the leaf spring by undo-
ing the nuts.
8.Remove the leaf spring assy by undoing the flex-
ible support pin.
9. Remove the leaf spring assy from the vehicle.
10. Detach the shoe of the leaf spring A and its
lock B from the leaf spring assy (in vans).
11. Remove the leaf spring shackle from the chassis.
SS - 717
Check the following:
1) Damage, 2) Damage or wear, 3) Damage, wear or deterioration,4) Wear 5) Cracking, damage or
flattening, 6) Damage, wear or deterioration, 7) Bending or damage, 8) Damage or wear, 9) Damage,
wear or deterioration.
Installation
1. Fix the leaf spring pad A and its stop B to
the leaf spring (in vans).
2. Temporarily fit the leaf spring on the chassis to-
gether with the elastic support and the nut.
3. Temporarily fit the leaf spring shackle with the
bushings and the nut.
4. Fix the elastic plate and the leaf spring buffer.
5. Fit the U-bolts and tighten the nuts.
U-bolt - Leaf spring buffer 44 54
SS - 718
6. Fit the rear wheel.
7. Lower the vehicle. Move the vehicle rear sus-
pension, upwards and downwards, two or three
times to stabilise suspension.
8. With the vehicle unloaded, tighten the following
sections:
Elastic pin support side nut
Leaf spring subassembly upper and lower section nut
Spring support pin - Leaf spring assembly. 88 108
Leaf spring shackle support nut.
Shock-absorbers removal
SS - 719
COMPONENTS
1. Hexagon nut
2. Spring washer
3. Shock absorber buffer washer
4. Hexagon nut
5. Spring washer
7. Shock absorber
10. Buffer
11. Buffer
Removal
N.B.
2. Hold the differential housing with a workshop
jack.
3. Disconnect the battery +and - terminals.
4. Remove the battery container, undoing the
three bolts/clips and 1 ground bolt (only on vans).
5. Remove the rear shock absorber, unscrewing
the hexagon nuts from the bodywork (upper sec-
tion A) and from the axle shaft housing (lower
section B) .
6. Detach the buffers and the buffer washers in the
upper and the lower section.
SS - 720
Check
1. Check the following parts.
A. Damage
B. Distortion, damage causing oil leaks and mal-
function
C. Damage and wear
2. Shock absorber operation check.
Pushing the piston rod, check that trac-
tion is uniform from the beginning to the
end of the stroke and that there is no
abnormal resistance or noise.
Push the piston rod to the end and un-
lock it. Make sure that it returns at a
constant speed from the beginning to
the end.
If the shock absorber operation fails,
replace it.
- DISCHARGE THE GAS COMPLETELY BEFORE DISPOS-
ING OF THE SHOCK ABSORBER.
Installation
1. Fit the rear shock absorber with the buffer washers and buffers and tighten the hexagon nuts.
Upper Section
Rear shock absorber - Chassis (upper part) 34 54
Rear shock absorber for chassis (lower part)
34 54
SS - 721
2. Lower the vehicle.
- MAKE SURE THAT THE HEXAGON NUTS HAVE BEEN
PROPERLY FITTED, SINCE UPPER SECTION AND LOWER
SECTION LENGTHS ARE DIFFERENT.
Verifiche
Noise
Move the wheel upwards and downwards, holding
it up with both hands as shown in the figure.
Check that the wheel bearing does not have an
excessive clearance.
Also check for abnormal noises when turning the
wheel.
Inspection
Visually inspect the suspension checking for signs
of wear and damage.
Noise check
Check attachments by moving the suspension
manually.
KEY:
1. Shock absorber
2. Leaf spring
Shock Absorbers
Inspection
Visually inspect all the shock absorbers and check that there are no signs of deterioration and fluid
leaks.
Operation check
SS - 722
Push the rear part of the vehicle with downward force in order to check the damping capacity of the
shock absorbers.
SS - 723
INDEX OF TOPICS
TIPPER VERSION VR
KEY:
1. Reservoir
2. Hydraulic control unit
3. Cylinder or jack
4. Tie rods
5. Thrust angle
6. Pins
7. Tilting hinges
8. Counter-chassis
9. Cross-member
10. Loading deck
11. Tailboard
12. Tailboard closing
13. Limit switch
14. Raised loading deck warning light switch
15. Safety prop
PORTER 1.3 16V Tipper version
VR - 725
Circuito idraulico
KEY:
1. Hydraulic piston
2. Hose break valve
3. One-way valve
4. Hydraulic pump
5. Electric motor
6. Pressure regulating valve
7. Flow regulating valve
8. Solenoid valve
9. Oil filter
Tipper version PORTER 1.3 16V
VR - 726
Schema impianto elettrico ribaltabile
ELECTRIC DIAGRAM - TIPPER:
1. Battery
2. 80A Fuse
3. Electric motor electromagnet
4. 7.5A Fuse
5. A/B loading deck ascent / descent switch
6. Loading deck maximum ascent limit switch
7. Relay
8. Solenoid valve
9. Raised loading deck horn (Buzzer)
10. Raised loading deck warning light
11. Blinker
12. Raised loading deck signal switch
13. Tipper electric pump motor
VR - 727
Smontaggio - Montaggio pianale ribaltabile
Tipper removal
Brake the vehicle.
Lift the tipper via the button located in the cab up
to its maximum height.
Insert the safety rod as in the figure, afterwards,
slightly lower the tipper so that the weight is un-
loaded onto the rod.
Remove the two clamps which connect the tipper
to the lifting arm.
Press and hold down the button for the descent,
cause the lifting arm to fold by applying force on it
so as to simulate the force applied by the tipper
during regular operation.
MAKE SURE THAT THE THRUST PISTON RE-ENTERS
COMPLETELY.
At this stage, the only constraint to removing the
tipper is the two hinges shown in the figure.
With the two spanners, remove the nut and release
the spring. Do not remove the pin during this op-
eration.
VR - 728
Now it is necessary to lower the tipper to continue
removal.
Slightly lift the tipper and release the safety prop,
then lower the loading deck carefully.
PERFORM THIS OPERATION VERY CAREFULLY, IT
COULD BE EXTREMELY HAZARDOUS FOR THE OPERA-
TOR.
Remove the two screws which act as a pin for the
hinge.
To perform this operation, it is necessary to slightly
lift the loading deck so that the two pins can be
released. Slide off the screw from its seat, and pull
the tailboard unlocking lever.
Now the tipper can be removed by lifting and then
resting it on the ground using two supports so that
the mudguards do not touch the ground.
Tipper refit
To refit the tipper, it is necessary to lift it from the
ground and place it on the vehicle with the aid of
the front reference pin as shown in the figure.
Fit the screws with the tailboard locking lever in the
hinges following the removal operations but in re-
verse order. To facilitate this operation it is neces-
sary to slightly move the deck vertically or
horizontally so as to align the deck and the vehicle
chassis holes. Once this operation is finished,
place the relevant nut with washer on the screw
but do not tighten it.
VR - 729
Manually raise the deck to the maximum tilting po-
sition and position the safety prop.
Tighten the hinge bolt to the prescribed torque.
Hinge bolt 41 - 49 Nm
Hooking the hydraulic jack lift arm to the tipper. To
perform this operation, raise the jack with the suit-
able button placed in the cab and take it up to the
maximum travel range (automatically reached
thanks to the limit switch ascent). Not being con-
nected to the deck, it will be checked that the arm
goes in the direction opposite to the desired direc-
tion (vehicle front part). In order to solve this prob-
lem, during the ascent, firmly hold the part
connecting the arm and the deck, forcing it towards
the rear part of the vehicle. During this operation,
pay attention not to unintentionally press the as-
cent limit switch which would lock the jack ascent.
Insert the two lift arm retainers on the deck and tighten to the prescribed torque.
Lift arm retainer for tipper 75 - 88 Nm
Remove the safety prop and lower the tipper with
the button placed in the cab. The descent limit is
determined by the activation of a limit switch by
this deck.
VR - 730
Smontaggio - Montaggio martinetto idraulico
Hydraulic jack fitting
For fitting, follow the removal operations but in re-
verse order. Observe the correct tightening torque.
hydraulic jack retainer for chassis 74 - 88 Nm
Fasten the oil fitting coming from the pump, to the
hydraulic piston, by fitting the two copper gaskets,
while respecting the tightening torque.
oil fitting 29 - 39 Nm
Hydraulic jack removal
To carry out this operation, first detach the jack
from the tipper.
Remove the screw fixing the oil fitting to the piston
as shown in the figure, taking the necessary pre-
cautions against oil leakage that will occur.
Remove the bolt fixing the jack assembly to the
vehicle chassis, then remove the whole lifting de-
vice.
Pompa idraulica e motore elettrico
VR - 731
Smontaggio
Hydraulic pump and electric motor removal
Before carrying out this operation, it is necessary
to lift the tipper, position the safety prop, release
the jack from the tipper and take it to the rest po-
sition.
Disconnect the oil fitting pipe on the pump, pay at-
tention to any possible oil leaks.
Disconnect the negative cable (-) from the battery.
Disconnect the pump unit electric motor power
supply cable.
Disconnect the pump unit motor remote control
switch excitation cable pin.
Remove the safety screw and disconnect the con-
trol pin of the solenoid valve for the jack descent.
Undo the two screws supporting the hydraulic
pump which can be accessed from the vehicle
right side. During this operation it is necessary to
hold the pump, as the two screws are indeed the
only connections between the hydraulic pump and
the vehicle chassis.
Smontaggio particolari
Removal of pump parts
Place the pump body in a vice. Undo the screws
locking the two plates which support the oil reser-
voir, remove the clamp and the reservoir also tak-
ing out the O-ring.
Slide off the oil intake pipe taking it out from its
seat.
VR - 732
With a hexagonal spanner remove the four Allen
screws to take out the pump.
Remove the O-ring which guarantees the sealing
between the pump body and the valve body.
Remove the oil filter taking out the three Allen
screws.
Smontaggio corpo valvole dal motore elettrico
Removing valve body from the electric motor
Remove the two screws fixing the electric motor to
the hydraulic pump.
Smontaggio valvole
Valve body removal
From the hole uncovered by the oil fitting removal,
it is possible to undo the flow control valve with a
screwdriver.
VR - 733
Remove the plastic protection manually and after-
wards unscrew the pressure relief valve and the
check valve.
Unscrew the solenoid of the solenoid valve to
check the jack descent acting on the knob as
Finally, remove the valve body by acting on the nut
Montaggio valvole
Valve body fitting
Before refitting the valve body, it is necessary to clean all the ducts thoroughly.
Wash with mild solvents and afterwards blow with compressed air.
Place the valve body in its seat located in the valve body and tighten to the prescribed torque.
valve body for valve body 25 - 30 Nm
Fit the solenoid in the seat located in the solenoid
valve and tighten to the prescribed torque.
Solenoid for valve body 5 - 6 Nm
VR - 734
Successively insert the one-way valve in its seat
and the pressure relief valve, locking it to the pre-
scribed torque.
One-way valve for valve body 25 - 30 Nm
Insert the flow control valve in its seat and start it
until it has reached the stop. Afterwards, tighten to
the prescribed torque, the appropriate socket head
cap on the head.
Flow control valve for valve body 20 - 25 Nm
Montaggio corpo valvole dal motore elettrico
Fitting the valve body to the electric motor
For this operation proceed with the fitting opera-
tions but in reverse order and tighten to the pre-
scribed locking torque.
valve body for electric motor 10 - 12 Nm
Montaggio particolari
Assembly of pump parts
Fit the oil filter after cleaning and blowing it with compressed air, and lock it by tightening the three
screws to the prescribed torque.
hydraulic oil filter 8 Nm
Before carrying out the following operation make sure that the contact surfaces between the valve body
and the pump are perfectly smooth and have no dents.
Fit a new O-ring in the specific slot located in the valve body. Before this operation, immerse the O-ring
in oil for about 10 min.
VR - 735
Fit the hydraulic pump and tighten the four Allen screws to the prescribed torque.
hydraulic pump for valve body 12 Nm
Proceed by inserting the oil intake pipe in the
pump. Fit a new O-ring, then install the reservoir
by first locking it with the two plates, and then with
the clamp.
WHILE INSTALLING THE RESERVOIR, IT IS ADVISABLE
TO LUBRICATE THE O-RING AND THE TWO FAYING SUR-
FACES WITH USED OIL TAKEN FROM THE PUMP.
Montaggio
Hydraulic pump and electric motor fitting
Place the pump with electric motor on the vehicle chassis bracket, fix the two screws, tightening them
to the correct torque.
pump assembly for chassis bracket 26 - 39 Nm
Connect the connection sleeve between the pump and the hydraulic piston with the specific copper
gaskets and lock it.
oil fitting 29 - 39 Nm
Restore all the electric connections following re-
moval operations but in reverse order.
VR - 736
Verifica e taratura della valvola limitatrice di pressione
Pressure relief valve check and calibration
If the loading tipper can not be raised, the cause
may be almost certainly attributed to an operation
failure or an incorrect calibration of the pressure
relief valve.
It is therefore necessary to operate so as to restore
correct operation.
Before adjusting, it is necessary to make some
preparations.
Make sure that the tipper is completely lowered.
Remove the plastic protection of the pressure re-
lief valve.
Fit a pressure gauge which can resist high pres-
sure (full scale about 300 Bar) on the connection
sleeve between the hydraulic piston and the pump.
Remove the maximum ascent limit switch by operating on the specific nut as shown in the figure.
TAKE ALL POSSIBLE PRECAUTIONS WHILE PERFORMING THESE OPERATIONS, CLOSE ALL
THE CONNECTIONS PROPERLY. REMEMBER THAT 200 BAR CATEGORY PRESSURES ARE
VERY DANGEROUS FOR BOTH USERS AND THE EQUIPMENT BEING USED.
Activate the tilting system.
Once the loading body is completely raised, press
the ascent button for a few seconds . In these con-
ditions the pressure relief valve is automatically
activated. When the valve mentioned before is ac-
tivated, a reading of about 130 Bar pressure shall
be displayed on the pressure gauge.
If the pressure is lower than the 130 Bar specifi-
cation, loosen the nut and with a hexagonal span-
ner operate on the maximum pressure relief valve
set screw as shown in the figure.
By undoing the set screw, the pressure on the
pressure gauge shall decrease. By tightening the
set screw, the pressure on the pressure gauge
shall increase.
Take the pressure to the prescribed value and
tighten the nut to the prescribed torque.
VR - 737
A 130 BAR PRESSURE IS SUITABLE TO LIFT A WEIGHT
OF 750 KG WEIGHT AS SPECIFIED BY VEHICLE CHAR-
ACTERISTICS.
THE VEHICLE MUST NEVER LIFT A WEIGHT EXCEEDING
SUCH AN ACTION COULD IRRETRIEVABLY DAMAGE THE
LIFTING SYSTEM.
pressure regulator set screw 25 - 30 Nm
VR - 738
INDEX OF TOPICS
CHASSIS CH
Windscreen
Preparation
Tools and other equipment:
- Cable to work with (about 5 mm x 6 m): used to fit glass
- Bamboo spatula: used to fit glass
- Rubber hammer: used to fit glass
- Brush, etc.: used to apply water with soap
- Water with soap: used to fit glass easily
COMPONENTS:
1. Front wiper arm and brush
2. Windshield and sealing gasket
Removal
Removal (to be carried out by two individuals)
1. With a bamboo spatula (or with a plain slot
screwdriver, etc.) take out the sealing gasket from
the body by pressing on the edge.
This operation shall be carried out from inside the
cab.
2. Take out the windshield by pressing and, while levering from the inside, lift the upper part of the
sealing gasket from both ends.
Remove the windshield with the sealing gasket.
Chassis PORTER 1.3 16V
CH - 740
AT THIS STAGE, MAKE SURE TO APPLY EQUALLY DISTRIBUTED FORCE ON THE GLASS.
ALSO HOLD THE GLASS FROM THE OUTSIDE SO THAT IT DOES NOT COME OUT OF ITS SEAT.
Refitting
Fitting (to be carried out by two individuals)
1. Perform the following preliminary operations:
- Fix the sealing gasket onto the windshield glass.
- Prepare a cable A to work with, as shown in
the figure.
- Apply water with soap on the sealing gasket pe-
rimeter B so that it slides more easily.
2. Fit the windshield and the relevant gasket on the
frame so that these are properly fitted on their
seats.
Also make sure that the two wire ends hang inside
the vehicle.
3. Pull the wire, always from inside the cab, while
a second person, from the outside, slaps their
palms against the windshield surface adjacent to
the gasket so that this gasket is properly fitted in
its seat.
4. To fit the windshield slap the top of it with the
palms of your hands.
N.B.
NEVER USE GASKETS WHICH ARE DAMAGED, BROKEN,
ETC., SINCE THIS COULD CAUSE WATER INFILTRATION.
TO FACILITATE FITTING, USE A RUBBER HAMMER.
PORTER 1.3 16V Chassis
CH - 741
5. Front wiper arm and brush. For the fitting posi-
tion, see the figure.
Side windows
Preparation
Tools and other equipment:
- Cable to work with (about 5 mm x 6 m): used during the glass fitting
- Bamboo spatula: used during the glass fitting
- Rubber hammer: used during the glass fitting
- Brush, etc.: used to apply water with soap
- Water with soap: used to fit glass easily
COMPONENTS:
1. Side window protection strip (optional equipment)
2. Side glass and relevant gaskets
CH - 742
Removal
1. With a bamboo spatula (or with a plain slot
screwdriver, etc.) take out the sealing gasket from
the body by pressing on the edge.
This operation shall be carried out from inside the
cab.
2. Take out the glass by pressing and, by levering from the inside lift the upper part of the sealing gasket,
from both ends.
Remove the glass with the gasket.
AT THIS STAGE, MAKE SURE TO APPLY EQUALLY DISTRIBUTED FORCE ON THE GLASS.
ALSO HOLD THE GLASS FROM THE OUTSIDE SO THAT IT DOES NOT COME OUT OF ITS SEAT.
Refitting
1. Place the gasket on the side window glass.
2. Prepare a cable A to work with as shown in the
figure.
Apply water with soap on the sealing gasket pe-
rimeter so that it slides more easily.
3. Fit the side glass and the relevant gasket on the
frame so that these are properly fitted on their
seats.
Also make sure that the two wire ends hang inside
the vehicle.
4. Pull the wire, always from inside the vehicle,
while a second person, from the outside, slaps
their palms against the glass surface adjacent to
the gasket so that this gasket is properly fitted in
its seat.
5. To fit the windshield slap the top of it with the
palms of your hands.
NEVER EMPLOY GASKETS WHICH ARE DAMAGED, BRO-
KEN, ETC., SINCE THIS COULD CAUSE WATER INFILTRA-
TION.
CH - 743
Rear window
Rear window upholstery panel
TOOLS AND OTHER EQUIPMENT
Butyl tape To prevent water infiltration
MP grease To lubricate
Water with soap For a better gasket sliding
Brush, etc. To apply the water with soap
Wooden hammer To fit the support
Paint for touch-up For paint touch-ups after removal/fitting and adjustment
COMPONENTS
1. Rear window upholstery panel
Removal/Fitting
REMOVAL
Remove the rear window internal upholstery panel
using the special tool to take out the relevant re-
tainers.
COMPONENTS:
2. Panel
3. Retainer
FITTING
Fit the rear window internal upholstery panel.
Rear window
COMPONENTS:
1. Rear window protection strip
2. Window and sealing gasket
CH - 744
REMOVAL AND FITTING
1. Remove rear window protection strip.
2. Remove the rear window by following the same operations described for windshield removal/fitting.
Doors
Pannelli
COMPONENTS
1. Door opening handle
2. Inside handle
3. Circlip and spacer
4. Window lifter handle
CH - 745
5. Front door upholstery panel
Removal
1. Remove the screw fixing the door opening han-
dle. Remove the front door inside handle.
2. Remove the inside handle by taking out the two
screws.
3. With a cloth, remove the lever circlip and take
out the window lifter handle and collect the rele-
vant spacer.
4. With the special tool, remove the upholstery re-
tainers and take out the door upholstery panel.
Installation
1. Place the upholstery panel on the door, then fit
the retainers.
2. Fit the door opening handle by tightening the
relevant screw.
3. Fit the inside handle by tightening the two
screws.
CH - 746
4. Fit the window lifter handle with the spacer and
the circlip with the glass completely closed.
Serratura e maniglie
COMPONENTS:
1. opening control tie rod
2. Locking knob
3. Lock block with the retainer
4. Outside handle
5. Lock
6. Plate
Smontaggio
CH - 747
COMPONENTS:
1. Opening control tie rod
2. Lock knob
3. Lock block with retainer
4. Outside handle
5. Lock
6. Plate
1. Remove the front door upholstery panel (see the
"Front Door Panel Upholstery Removal" section).
2. Remove the locking knob.
3. Remove the lock, along with the opening control
tie rod by undoing the three screws.
CH - 748
4. Remove the lock block by taking out the relevant
retainer.
5. Remove the outside handle by undoing the two
nuts.
Installation
1. Fit the outside handle by screwing the two nuts
A.
2. Fit the lock block with the relevant retainer
3. Fit the lock by screwing the three screws.
N.B.
- APPLY MP GREASE ON EACH OF THE SLIDING SEC-
TIONS SHOWN IN FIGURE B.
4. Fit the door opening control tie rod.
5. Fit the door locking knob.
6. Fit the door upholstery panel and the relevant components.
N.B.
AFTER FITTING, CHECK AND ADJUST THE LOCK.
CH - 749
Dispositivo alzacristallo
COMPONENTS (only Pick-up):
1. External gasket
2. Internal gasket
3. Side gasket
4. Front door glass
5. Window lifter
6. Limit switch
7. Rear frame
8. Rear guide
9. Front frame
10. Front guide
Removal
1. Remove the front door upholstery panel.
2. Remove the inspection cover.
- REMOVE THE BUTYL TAPE SO AS NOT TO DAMAGE THE
INSPECTION COVER.
CH - 750
3. Remove the external gasket of the front door
glass.
4. Remove the internal gasket of the front door
glass.
5. Remove the glass side gasket.
- LIFT THE EXTERNAL GASKET TOOTHED SECTION. THIS
WILL FACILITATE REMOVAL.
- ONCE REMOVAL IS FINISHED, TURN THE GASKET
TOOTHED SECTION BACK INTO THE ORIGINAL POSI-
TION.
6. Front door glass removal
- Remove the rear frame and the front frame by
unscrewing the bolts indicated in the figure.
- Remove the two bolts fixing the front door glass
unit.
- Remove the glass from the front door.
- Keeping the glass in vertical position, pull it up-
wards.
- Draw a reference mark on the front side of the
glass to identify the correct limit switch refitting po-
sition.
Installation
1. Front door glass unit fitting.
- Apply the MP grease on each window lifter sliding
section.
- Fit the front door window lifter with the three bolts.
- Insert the front door glass unit and tighten with
two bolts temporarily.
2. Fit the side gasket in its relevant seat.
3. Tighten the two bolts.
- MAKE SURE THAT THE GLASS IS CORRECTLY FITTED
IN THE FRONT DOOR.
CH - 751
4. Tighten the rear frame bolt, then tighten the two
front frame bolts.
5. Fit the inspection cover.
6. Fit the door upholstery panel.
7. Fit the door upholstery panel components.
Regolazioni
Door alignment adjustment
FRONT DOOR
Prescribed alignment sizes
Distance A, B, C, D Specified value: 3.5 - 7.5 mm
Tolerance for each side A, B, C Specified value:
not exceeding 1.5 mm
Tolerance for each side D Specified value: not ex-
ceeding 2.0 mm
Height difference Specified value: not exceeding
1.5 mm
CH - 752
Tolerance between the right and left side A, B, C,
D Specified value: not exceeding 2.0 mm
1. Adjustment in height and towards right/left
Adjust after undoing the two door side hinge bolts.
2. Adjustment in height and longitudinal direc-
tion
Adjust after undoing the two strut side hinge bolts.
3. Door locking plate adjustment
Undo the screw. Adjust and tighten the plate so
that the door remains closed.
Porte Scorrevoli
Sliding door frame
COMPONENTS:
1. Frame glass guide
2. Glass frame
Sliding door upholstery panel
CH - 753
Removal
1. Remove the door upholstery panel and the in-
spection cover.
2. Remove the side gasket.
3. Remove the glass frame by undoing the relevant
bolt.
Installation
1. Fit the glass frame by tightening the relevant
bolt.
- BEFORE FITTING, APPLY ADHESIVE AT THE REAR
PART OF THE GLASS GUIDE.
2. Fit the guide.
3. Fit the inspection cover and the door upholstery
with the relevant components.
KEY:
1. Adhesive
2. Guide
CH - 754
Pannelli
Components
1. Door inside handle and relevant circlip
2. Circlip and spacer
3. Window lifter handle
4. Sliding door upholstery panel
Sliding door upholstery panel
Upholstery panel removal
1. Using a cloth, remove the circlip and take out
the door internal handle.
2. Using a cloth, remove the circlip and take out
the window lifter handle and collect the relevant
spacer.
CH - 755
3. With the special tool, remove the upholstery re-
tainers and take out the door upholstery panel.
Installation
1. Place the upholstery panel on the door, then fit the retainers.
2. Fit the window lifter handle with the spacer and the circlip (see the figure for correct fitting position).
3. Fit the inside handle with the glass completely closed.
COMPONENTS:
1. Door locking knob
CH - 756
2. Control unit locking the sliding door
3. Tie rod
4. Outside handle
5. Locking frames
6. Door lock
7. Retention plate
Removal
1. Remove the door upholstery panel and the in-
spection cover.
2. Remove the door locking knob.
3. Remove the sliding door locking control unit by
undoing the two screws.
4. Remove the tie rod.
5. Remove the outside handle by undoing the two
relevant nuts.
6. Remove the locking tie rod by disconnecting it
from the outside handle unit.
7. Remove the door lock by taking out the two rel-
evant screws.
CH - 757
INSTALLATION
1. Apply MP grease on each of the sliding sections.
2. Fit the door lock by tightening the two relevant
bolts.
3. Connect the locking tie rod.
4. Fit the outside handle by tightening the two rel-
evant nuts.
5. Fit the tie rod.
6. Fit the control unit locking the door lock with the
two relevant screws.
7. Fit the door locking knob.
8. Fit the inspection cover and the door upholstery with the relevant components.
Dispositivo alzacristallo
CH - 758
COMPONENTS:
1. External gasket
2. Internal gasket
3. Side gasket
4.Inspection cover
5. Bolt
6. Sliding door glass
7. Bolt
8. Window lifter unit
9. Lower gasket
10.Glass support groove
11.Frame
Removal
1. Remove the door upholstery panel.
2. Remove the inspection cover.
3. Remove the external gasket of the sliding door
glass.
4. Remove the internal gasket.
5. Remove the side gasket B.
- REMOVE THE BUTYL TAPE SO AS NOT TO DAMAGE THE
INSPECTION COVER.
6. Loosen the frame unit bolt.
7. Sliding door glass removal.
- Remove the two glass retention bracket bolts A.
CH - 759
- Remove the glass from the outside, starting from
the front/ upper part, with the glass tilted back-
wards.
8. Separate the glass support groove from this
glass.
- IMMEDIATELY DRAW A REFERENCE MARK ON THE
GLASS TO IDENTIFY THE CORRECT REFITTING POSI-
TION OF THE GROOVE.
KEY:
A:Front part.
9. Remove the window lifter unit by undoing the
three bolts.
Installation
1. Fitting the glass support groove lower gasket.
- Draw a reference mark on the glass to identify
the correct fitting position of the lower gasket and
the groove.
- Apply water with soap inside the lower gasket.
- To place the gasket and the groove properly, use
a wooden hammer.
CH - 760
- Insert the glass inside the door, starting from the
lower part, with the glass tilted forward.
2. Fit the glass on the retention bracket A with
the relevant bolts.
3. Tighten the frame bolt.
4. Fit the side gasket.
5. Fit the internal gasket.
6. Fit the external gasket.
CH - 761
7. Fit the inspection cover.
8. Fit the door upholstery panel and the relevant
components.
- APPLY THE BUTYL TAPE, WITHOUT EXTENDING IT,
ALONG THE INSPECTION COVER GROOVE.
- ONCE THE OPERATION IS FINISHED, PRESS ON THE
COVER APPLICATION PART.
- IF THE INSPECTION COVER SHOWS SIGNS OF DAM-
AGED, ETC., THERE MAY BE WATER INFILTRATION.
Guide e rulli
COMPONENTS:
1. Sliding door
2. Guide roller pin
3. Upper roller arm
4. Upper roller arm support
5. Lower roller arm
6. Pin and lower bearing
7. Roller pin guide and lower roller
8. Cap
9. Screw
10. Upholstery
11. Limit switch
12. Central hinge
13. Pin and central bearing
CH - 762
14. Guide roller pin and central roller
15. Central guide
A = Sliding door hinge upper rollers
B = Sliding door roller
C= Central hinge
Upper roller removal
1. Hold the sliding door with a jack, interposing a
wooden wedge as shown in the figure.
2. Remove the door glass gasket
3. Unscrew the two nuts and remove the upper
roller arm support.
4. Remove the upper roller arm by taking out the
relevant pin, using an Allen wrench.
5. Remove the upper roller arm from the body.
CH - 763
Lower roller removal
2. Remove the lower roller arm by taking out the
two relevant bolts.
3. Remove the guide roller pin and the lower roller
from the lower roller arm, using an Allen wrench.
Central hinge removal
N.B.
- CARRY OUT THIS OPERATION WITH ANOTHER PERSON
TO KEEP THE DOOR IN POSITION.
2. Remove the side upholstery.
3. Remove the central guide upholstery.
N.B.
- THE UPHOLSTERY IS HELD BACK BY TOOTHED HOOK.
THEN MOVE THE UPHOLSTERY IN THE DIRECTION INDI-
CATED BY THE ARROW AND, AFTERWARDS, REMOVE IT
FROM THE FRONT SECTION OUT OF THE VEHICLE.
CH - 764
4. Remove the limit switch A by undoing the two
relevant bolts.
5. Remove the central hinge by taking out the two
relevant bolts.
N.B.
- SLIDE THE DOOR AND, THEN REMOVE THE UPPER
ROLLER AND THE CENTRAL HINGE FROM THE GUIDE,
STARTING FROM THE REAR (REMOVAL SECTION)
6. Remove the guide by taking out the three rele-
vant nuts.
Upper roller removal
1. Apply MP grease onto each of the sliding sections.
2. Fit the upper roller arm support on the door with the two relevant nuts.
N.B.
THE NUTS SHALL BE COATED WITH A LAYER OF PAINT.
3. Fit the upper roller arm to the support with the
relevant pin indicated in the figure, using an Allen
wrench.
4. Insert the arm in the track section.
5. Remove the jack.
CH - 765
Lower roller fitting
1. Apply MP grease onto each of the sliding sec-
tions.
2. Fit the guide roller pin and the lower roller on the
lower roller arm, using an Allen wrench.
3. Fit the lower roller arm on the door with the two
relevant bolts.
4. Remove the jack under the door panel.
Central hinge fitting
tions.
2. Fit the guide by tightening the three relevant
nuts.
3. Fit the central hinge by tightening the two rele-
vant bolts.
4. Fit the limit switch by tightening the two relevant
bolts.
5. Fit the central guide upholstery.
6. Remove the jack.
CH - 766
Regolazioni
Sliding door
Distance B, G, H <Specified value: 3.5 - 7.5 mm
Tolerance for each side B, G Specified value: not
exceeding 1.5 mm
Tolerance for each side H Specified value: not ex-
ceeding 2.0 mm
Height difference Specified value: not exceeding
1.5 mm
Tolerance between the right and left side B, G, H
Specified value: not exceeding 2.00 mm
Height adjustment
1. Adjust after undoing the two fixing bolts.
Now, move the catch at a distance equal to the
lower roller movement.
Characteristic
Adjustment tolerance
~2 mm
2. Adjust after undoing the two central hinge fixing
bolts.
Characteristic
~2 mm
Adjustment in longitudinal direction
Adjust after undoing the two central hinge fixing
bolts.
If after adjusting the central hinge, the door front
side distance (point G) is excessively narrow, ad-
just by inserting a shim washer in the section fixing
the lower catch.
Characteristic
CH - 767
~2 mm
Thickness height:
1 mm
Adjustment of height difference
1. The adjustment is carried out after loosening the
lower roller fixing bolt.
Characteristic
~2 mm
2. The adjustment is carried out after loosening the
screw fixing the lock striker plate.
IF THE DOOR REAR SECTION IS LOWERED OR LIFTED,
NEVER TRY TO CORRECT THE TRIM BY OPERATING ON
THE DOOR LOCKING PLATE. ADJUST BY OPERATING ON
ITS HINGE.
Characteristic
~2 mm
3. Move the lower catch at a distance equal to the
movement.
- Temporarily fit the door by tightening the bolts
fixing the lower catch.
- After opening/closing the door two or three times,
tighten the bolts tightly.
CH - 768
Portellone posteriore
COMPONENTS:
1. Rear shock absorber
2. Nut
3.Door hinge
4. Door
Removal
1. Remove the side shock absorbers by removing
the two relevant bolts.
N.B.
- APPLY ADHESIVE TAPE IN ORDER TO AVOID DAMAG-
ING THE DOOR INSIDE PANEL DURING REMOVAL AND
FITTING.
2. Remove the nuts from the door hinges.
3. Disconnect the heated rear window device (if
fitted).
4. Remove the door from the body.
CH - 769
Installation
1. Fit the door on the body.
2. Connect the heated rear window device (if fit-
ted).
3. Tighten the door hinge nuts.
4. Fit the side shock absorbers by tightening the
two relevant bolts.
5. Align the door with respect to the body.
Tail door support - Tail door 17.7 23.5
Rear door panel
Rear door upholstery panel
COMPONENTS:
1. Rear upholstery panel
Removal/Fitting
REMOVAL
1. Remove the door upholstery panel using the special tool to take out the relevant retainers.
FITTING
1. Fit the door upholstery panel.
CH - 770
COMPONENTS:
1. Block fixing device
2. Lock block
3. Door lock
4. Retention plate
Removal
1. Remove the door upholstery panel.
2. Remove the door lock block by taking out the
relevant block fixing device.
3. Remove the lock block by taking out the two rel-
evant bolts.
4. Remove the retention plate by taking out the two
relevant bolts.
CH - 771
Installation
tions.
2. Fit the retention plate by tightening the two bolts.
3. Fit the lock block by tightening the two relevant
bolts.
4. Fit the lock block using the fixing device.
5. Check and adjust the locking device.
Regolazioni
Door panel
J distance
Prescribed value: 3.6-8.6 mm
K distance
P distance
(Standard)
(Not standard)
Tolerance for each side
Prescribed value: Not exceeding 2.0 mm
Height difference:
Tolerance between right and left sides
CH - 772
Adjustment in longitudinal direction of the up-
per section
Adjust after undoing the body side hinge bolts.
- When the upper section is adjusted in longitudinal direction,
make sure that the distance between the rear window support
side surface and the door side surface does not exceed 4.6 -
8.6 mm.
- Considering the adjustment, that shall not exceed 2.0 mm,
loosen the door side hinge bolts.
Adjustment in longitudinal direction of the low-
er section and closing adj.
Carry out adjustments by changing the fitting po-
sition of the lock plate.
Front bumper
COMPONENTS:
1. Screws
2. Bumpers
CH - 773
Removal
1. Remove the front panel
2. Loosen the eight screws and detach the front
bumpers from the two upper clips.
Refit
For refit, follow the previous operations in reverse.
Replacing the exhaust
Catalytic converter replacement
1. Remove the front pipe by undoing the relevant
fixing bolts.
2. Remove the catalytic converter by undoing the
relevant fixing nut on the main silencer.
CH - 774
3. Install the new catalytic converter and tighten
the relevant fixing nuts using a new gasket.
4. Tighten catalytic converter fixing bolts and the
front pipe fixing nuts to the prescribed torque using
new gaskets.
Exhaust pipe - Catalytic converter 42 56
5. Start the vehicle and check if there are leaks from the catalytic converter flanges.
Light unit
COMPONENTS:
1. Clip
2. Headlamp support
3. Front/side turn indicator
4. Headlamp
CH - 775
Removal
1. Remove the front panel
2. Unscrew the fixing screw.
Remove the headlamp protection.
3. Remove the turn indicator fixing spring.
4. Take out the unit from the vehicle.
5. Disconnect the connector and remove the turn
indicator.
CH - 776
6. Loosen the two fixing screws shown in the fig-
ure.
7. Remove the retention clip from the front panel.
8. Loosen the two screws fixing the headlamp.
9. Remove the retention clip located at the lower
part, then remove the headlamp.
Refitting
For refit, follow the previous operations in reverse.
Mascherina anteriore
Removal
1. Release the upper pins from the clips and tilt
panel 1 forward.
2. Release the panel from the lower pins and re-
move it.
CH - 777
Refitting
1. Place hooks A on pins B
2. Tilt the panel and fix pins C in clips D
Front panel components
CH - 778
Instrument panel
COMPONENTS:
1. Panel for combined instrument panel
2. Combined instrument panel
3. Central panel for instrument panel
4. Glove-box lid
5. Glove-box
6. Brake oil reservoir housing cover
7. Cap for instrument panel holes
8. Panel upper cover
9. Sleeve No.. 2 for defroster
10. Switches
11. Instrument panel (assembly)
CH - 779
Removal
Starting operations
1. Disconnect the battery negative cable.
2. Remove the steering wheel (steering section
reference).
3. Pull out the panel of the instrument panel.
4. Remove the instrument panel and the warning
lights by taking out the five screws.
5. Disconnect the speedometer cable and electric
connections.
6. Remove the diffuser hand grip by taking out the
relevant screw.
7. Take out the heating adjustment lever.
8. Central upholstery panel removal.
- Remove the two screws.
- Remove the clip.
- Take out the panel.
9. Remove the heating adjustment unit.
Removing the upper panel of the instrument
panel and the glove compartment
1. Press firmly the left end section A as shown in
the figure, operating in the direction indicated by
the arrow. Then, open the section joint B. Fit a
screwdriver wrapped with protective tape in order
to disconnect section B.
2. Insert a screwdriver in section C so as to detach
it.
CH - 780
3. Lift section B so as to detach section D.
(Pay attention not to scratch the instrument panel
with the clip of section C).
4. Detach the fitting of section E.
5. Remove the object-holding drawer/glove-box
compartment and the relevant lid by taking out the
seven screws.
Instrument panel removal
1. Lift the cover using a plain slot screwdriver wrapped around with a cloth, then remove the brake fluid
reservoir inspection cover.
Pay attention so as not to scratch during removal.
2. Remove the brake fluid reservoir by taking out
the two bolts.
3. Remove the instrument panel by taking out the
seven bolts.
CH - 781
4. Remove the reinforcing bracket from the body
by taking out the eight bolts.
CH - 782
Removing air vents/loudspeakers/cigarette
lighter
1. Remove the diffuser assembly by taking out the
five screws.
2. Remove the right and left side air vent clip.
3. Remove the right side air vent.
4. Remove the central and left air vents by taking
out the three screws.
5. Remove the two openings by taking out the four
screws.
6. Remove the loudspeakers by taking out the two
screws.
7. Remove the cigarette lighter support bracket by
taking out the two screws.
Instrument panel installation
1. Fit the instrument panel on the body and tighten
the seven bolts.
CH - 783
2. Fit the brake fluid reservoir with the two bolts.
3. Fit brake fluid reservoir inspection lid.
4. Fasten the cover in the relevant seat.
5. Fit the upper panel of the instrument panel in the
relevant seat.
CH - 784
6. Fit the object-holding drawer/glove-box com-
partment with the relevant lid using the seven
screws.
7. Connect the rear section of the unit.
8. Fit the heating adjustment panel with the two
screws.
9. Central upholstery panel installation:
Fix the lower section with the clip
Place the panel in the relevant seat
Tighten the two screws
10. Fasten the heating adjustment hand grips.
CH - 785
11. Fit the diffuser hand grip with the relevant
screw.
12. Connect the speedometer and electric con-
nections.
13. Fit the instrument panel and the warning lights
with the five screws.
14. Fit instrument panel upholstery frame.
15. Fit the steering wheel (see the "Steering" sec-
tion).
16. Connect the battery negative terminal.
Installation
Refitting air vents/loudspeakers/cigarette
lighter
1. Fit the cigarette lighter support bracket with the
two screws.
2. Fit the loudspeakers with the two screws.
3. Fit the right and left side resistors with the four
screws.
4. Fit the central and left air vents with the three
screws.
5. Fit the air vent and, afterwards, place the clip.
6. Fit the diffuser assembly by tightening the five
screws.
CH - 786
Starting operations
Fit the reinforcing bracket on the body and tighten
the eight bolts.
CH - 787
Sedili - Cinture di sicurezza
KEY:
1. Seat back for front seat
2. Seat back upholstery
3. Gasket
4. Engine inspection cover
5. Central mat
6. Front seat cushion
7. Cushion upholstery
CH - 788
Van front seat
KEY:
1. Front seat inclination adjustment
2. Seat back for front seat
4. Bushing
5. Gasket
6. Engine inspection cover
8. Central mat
9. Internal guides
10. Front seat cushion
CH - 789
KEY:
1. Screw
2. Seat back fastener
3. Seat back fastener subassembly for rear seat
4. Ring
6. Seat back cushion
7. Screw
8. Cushion
9. Ring
11. Rear seat cushion
Check
Check-up of inclination angle until the clicking
sound of the belt with winder is heard
1. Lean slightly the winder from the fitting angular
position. Make sure that the belt lock is not re-
leased in any direction with an inclination angle of
15 degrees.
CH - 790
2. Make sure that the belt remains locked when the
inclination angle is exceeds the 45 degrees.
Never remove the winder.
Fitting the front seat internal bolt
Fit the front seat internal bolt assembly in the cor-
rect fitting position as shown in the figure.
KEY:
A. Left
B. Right
Safety belts
FRONT
Safety belt at three anchor points without winder
KEY:
1. Bolt
2. Bolt
3. Safety belt
4. Safety belt attachment
Safety belt at three anchor points with winder
KEY:
1. Bolt
2. Bolt
3. Screw
4. Safety belt
5. Safety belt attachment
CH - 791
Serbatoio carburante
COMPONENTS:
1. Cable harness (fuel pump)
Cable harness (fuel transmitter gauge)
2. Clamp & pipe (for breathing)
3. Clip & pipe (for fuel return)
4. Clip & pipe (for emissions)
5. Clip & pipe (for fuel main)
6. Bolt
7. Fuel tank unit
11. Vapour bleeding checking valve unit
12. Pipe
13. Fuel transmitter gauge unit
14. Fuel pump unit
CH - 792
KEY:
1. Cable harness (for fuel transmitter gauge)
2. Cable harness (for fuel pump)
3. Clamp & pipe (for fuel inlet)
5. Clip & pipe (for fuel main)
8. Bolt
11. Pipe (for emissions)
12. Vapour bleeding checking valve unit
13. Fuel transmitter gauge unit
14. Fuel pump unit
Removal
Remove the parts, as shown in the figure.
Refitting
To refit, follow the operations described above but in reverse order.
CH - 793
Fuel tank cap
Inspection
1. Remove tank cap from the fuel filler.
2. Check that the key can not be turned and re-
moved from the fuel tank cap.
3. Press the lever to check that the key can not be
turned and removed from the fuel tank cap.
4. Insert the fuel tank cap in the fuel inlet opening.
If faults are detected, replace the fuel tank cap with a new one.
CH - 794
INDEX OF TOPICS
PRE-DELIVERY PD
General inspection
Vehicle general check
Vehicle external appearance
Check for possible external damage of the vehicle.
- Bodywork paintwork
- Mouldings
- Window panes
- External mirrors
- headlamp glass
- Bumpers
Bodywork panel coupling
Check the correct alignment and closing of body-
work panels.
- Doors
Van
- Tail door
- Sliding door (side)
Pickup
- Side board
- Tailboard
Closing and hinge operation
Check the correct operation and lubricate if nec-
essary.
- Open and close with the key each door.
- Open and close each door with the internal lock.
Van
- Open the tail door with the key to check closing
and hinge operation.
- Close the tail door to check the lock operation.
Pickup
PORTER 1.3 16V Pre-delivery
PD - 797
- Release the locking levers of the side and the
tailboards for checking.
- Open the side and tailboards for checking.
Vehicle cleaning
External
Carry out the following operations:
1. With a low-pressure water jet, soften and rinse
caked dirt.
2. Wash the vehicle with a soft sponge and a mix
of water and car shampoo.
3. Rinse the car shampoo with a low-pressure wa-
ter jet.
4. Use a specific compound for any grease or tar
marks.
5. Thoroughly rinse the vehicle with water.
6. Dry the vehicle wiping from the top to the bottom
using a clean shammy cloth or a soft absorbing
cloth.
7. Check that water does not leak in.
8.Remove all the check labels from the vehicle
window glasses or mirrors
9. Adjust mirrors aiming.
Internal
Carry out the following operations:
1. Remove any trace of grease or dirt off the inter-
nal surfaces.
2. Completely remove all plastic covers from
seats, sun screens, instruments panel.
3. Vacuum upholstery and carpets.
4. Vacuum the boot.
5. Remove the protective film from the control pan-
el of the heating system.
6. Remove all the shipping information labels.
7. Clean all glasses and mirrors with a specific
compound.
Pre-delivery PORTER 1.3 16V
PD - 798
8. Check that all the optional parts are correctly
fitted and that they work properly.
User manual
Use and Maintenance Booklet - Warranty
Booklet
Make sure the following elements are in the glove-
box:
- Use and maintenance booklet
- Warranty Booklet
Tools
Check that the vehicle has the following compo-
nents:
1. Toolkit bag
Wrench for wheel hub nut
Wrench for spark plug
Screwdriver
2. Inflate/repair kit T.E.K. (Tire Emergency Kit)
Pick-up: placed in between the two seats.
Van: placed inside the left side rear loading com-
partment.
Wheel cover fitting
Wheel guard-central cover fitting
- Fit the central covers and the wheel guards,
slightly hitting, aligning the carved part (of the
wheel guard) with the air valve.
PD - 799
Tyre pressure
tyre pressure
Check inflation pressure.
Adjust inflation pressure of each tyre to the pre-
scribed value. (Tyre pressure is indicated on the
specific label affixed to the vehicle).
Nut tightening
Loosening the hub clamps
With a specific wrench, check that nuts and bolts
of the wheels are not loosened.
Wheel rim nuts - Wheel hub 88 118
Impianto di riscaldamento e ventilazione
Heating system operation - ventilation
Operation check:
- Check controls and make sure that the system
works properly.
Preliminary inspections
PD - 800
Cigarette lighter
Cigarette lighter:
Check if they works properly:
Press the lighter. This will disconnect automatical-
ly as soon as heated.
Take out the cigarette lighter and make sure that
the element is heated.
Seatbelt
Safety Belts
Check if they works properly:
- Fasten and release the buckle.
Adjusting devices
Adjustment devices of seat and seat back
locks
Check if they work properly.
PD - 801
Horn operation
Horn functioning
Check if the horn hoots each time that the button
is pressed.
Wipers operation
Windshield washer orientation adjustment
Insert a straight pin in the spray nozzle, then adjust
the position.
Gauge functions and rear window anti-fog de-
vice
Check the operation of the following gauges (after
engine warm-up).
- Fuel gauge.
- Temperature gauge
- Low fuel warning light.
Rear window anti-fog device
Check the warning light operation of the device
activated.
Set the anti-fog device switch to "ON".
The relevant warning light turns on.
PD - 802
Windscreen wiper and washer operation
Check:
- The windscreen wipers work easily.
- The windscreen washer fluid sprays at the centre
of the windshield.
External lights
External Lights
Check the operation of the following external
lights:
- Headlamps, high-beam and low-beam lights.
- Left and right turn indicators.
- Tail lights and stop lights.
- License plate lights
- Emergency lights.
- Reverse gear light.
- Rear fog guard lights.
- Internal light.
Headlight adjustment
Headlamp orientation
Check headlamp orientation.
1. Place the vehicle on level ground.
2. Act repeatedly on the front suspensions.
3. Swing the vehicle sideways repeatedly, then
take the vehicle to its regular position.
4. Clean the headlamp glass, then fit at their front,
the special checking tool and check the correct
orientation.
- Check headlamp orientation.
A = Transversal adjustment
B = Vertical adjustment
PD - 803
Warning lights
Warning lights (instrument panel)
Check the operation of warning lights. (The ignition
switch must be set to "ON").
Parking brake/engaged warning light: It turns
on if the parking brake lever is lifted.
Oil pressure warning light: On.
Battery/charging system warning light: On.
Emergency flashing warning light: It flashes in-
termittently if the emergency indicator switch is
lowered.
High-beam warning light: It turns on when the
turn indicator lever is pulled backwards.
Engine control warning light: On.
Chassis inspection
Checks to be carried out under the body
Brackets for the jack and support points for
safety supports
1. Support points for safety supports and dou-
ble upright lift.
The support points are arranged in four positions,
two on the right side and two on the left side.
Place the front part supports under the body strut.
Place the rear part supports on the leaf spring.
Never apply supports to the body.
PD - 804
2. Support points for workshop jack
Front side: apply the jack to the cross-member of
the front suspension.
Rear side: apply the jack to the lower section of the
differential
Leakages
Fluid leaks
Check for possible fluid leaks from the following components:
- Engine
- Transmission
- Differential
- Fuel pipe
- fuel tank and drainage plug
- Fuel internal filler
Riscontri porte
Door lock adjustment
1.Loosen the screws of the door striker square
plate.
2.Place the striker correctly and tap it with a plastic
hammer.
3.Tighten the door screws again:
Door stop plate - Chassis 20 - 30
PD - 805
Engine housing inspection
Battery connections
Check the following:
- Corrosion or slackness of connections.
- Battery terminals detached due to slackness.
Tighten connections or the terminal, if necessary.
Battery fluid
Check the level:
- Add distilled water up to the upper level if neces-
sary.
- The electrolyte specific weight shall exceed 1.25
at 20C.
Bellow joint
Sleeve connections and fluid pipes
Check the sleeve and fluid pipe connections.
- Check that there are no signs of leaks in the coolant pipes.
- Check that the hoses and the air inlet duct are properly connected.
Ignition timing
IGNITION TIMING - CHECKING AND ADJUSTMENT
- BEFORE CARRYING OUT THE IGNITION TIMING, CONNECT THE TESTER MULTIMETER
PROBE WITH THE DIAGNOSIS CONNECTOR GROUND TERMINAL.
- THE ENGINE SHALL NOT EXCEED THE INDICATED SPEED. BESIDES, OPERATE SO THAT
THE IGNITION TIMING IS STEADY.
1. Warm up the engine;
2. Connect the rpm indicator terminal to the diagnosis connector.
- AVOID CONTACT BETWEEN THE RPM INDICATOR TERMINAL AND GROUND SO AS NOT TO
DAMAGE THE ELECTRONIC CONTROL UNIT OF THE ELECTRONIC FUEL INJECTION AND/OR
THE IGNITION COIL.
- TAKING INTO ACCOUNT THAT SOME RPM INDICATORS ARE NOT COMPATIBLE WITH THIS
IGNITION SYSTEM, IT IS RECOMMENDED TO CHECK THE RPM INDICATOR COMPATIBILITY
WITH THE SYSTEM BEFORE ITS USE.
PD - 806
A) Rpm indicator terminal
B) Ground terminal
3. Connect the tester multimeter probe with the di-
agnosis connector ground terminal with the spe-
cial tools.
C) Ground
D) Special tool
E) Special tool
F) ECU-T
Specific tooling
4. Remove the inspection hole cap from the upper
side of the transmission.
5. Check with the stroboscopic gun (G) that the
ignition timing reference (yellow) on the flywheel is
aligned with indicator (H).
Ignition timing: 3 2 at idle speed; Before top
dead centre (BTDC).
G) Stroboscopic gun flash
H) Reference on the ignition timing inspection hole
PD - 807
6. Ignition timing adjustment
- Loosen the bolt fixing the camshaft sensor.
- Adjust the camshaft sensor position until the fly-
wheel ignition timing reference is aligned with the
indicator.
- IF THE CAMSHAFT SENSOR IS TURNED CLOCKWISE,
THE IGNITION TIMING IS DELAYED. CONVERSELY, IF THE
CAMSHAFT SENSOR IS TURNED ANTICLOCKWISE, THE
IGNITION TIMING IS ADVANCED.
7. Tighten the bolt fixing the camshaft sensor to the prescribed torque and check that the ignition timing
is not postponed.
Cylinder for spark plug 14.721.6
8. Disconnect the cable from the diagnosis connector.
Window cleaning liquid
Windshield washer fluid in the reserve tank
Check the level:
- The windshield washer fluid level in the reserve
tank must reach the maximum "FULL".
Add windshield washer fluid, if necessary.
Coolant
Coolant in the expansion tank
Check the level (when cold):
- The coolant level in the expansion tank must
reach the maximum "FULL".
Add (in the expansion tank) coolant special for
aluminium engines, if necessary.
PD - 808
Engine idle
Rpm indicator connection
Connect the rpm indicator measurement terminal
to the diagnosis connector.
- AVOID CONTACT BETWEEN THE RPM INDICATOR TER-
MINAL AND GROUND SO AS NOT TO DAMAGE THE ELEC-
TRONIC CONTROL UNIT OF THE ELECTRONIC FUEL
INJECTION.
- TAKING INTO ACCOUNT THAT SOME RPM INDICATORS
ARE NOT COMPATIBLE WITH THIS IGNITION SYSTEM,
CHECK THE RPM INDICATOR COMPATIBILITY BEFORE
ITS USE.
A) Rpm indicator terminal
B) Ground terminal
Adjust the throttle adjustment valve so that the idle
speed reaches the specified value. Specification:
900 50 rpm.
N.B.
- DO NOT ADJUST IDLE SPEED WHILE THE VACUUM
SWITCHING VALVE IS WORKING. BEFORE ADJUSTING
IDLE SPEED, CHECK THAT THE VACUUM SWITCHING
VALVE IS INACTIVE.
Idle speed adjustment
Preliminary operations for idle speed adjustment
- Warm up the engine (continue warming up the engine for other 10 minutes after the first radiator
electric fan activation).
- Check that all the accessory switches are set to OFF.
- Check that there is an air filter.
- Check that all the vacuum pipes are connected.
- Check that there are no air leaks in the intake system.
- Check that there are no air leaks in the exhaust system.
- On vehicles with manual transmission, position the gearshift lever in neutral.
- Pull the hand brake.
- Check that the throttle cable is correctly adjusted.
- Check that ignition timing is correctly adjusted.
- Check that the pipe system for engine oil vapour recovery (blow-by), works properly.
N.B.
DO NOT ADJUST IDLE SPEED WHILE THE RADIATOR ELECTRIC FAN IS WORKING.
PD - 809
Engine oil
ENGINE OIL
Check the level:
- Check oil level when the engine is hot.
Let the engine run for 2 or 3 minutes, then stop the
engine; add oil until reaching the MAX limit, if nec-
essary.
AGIP SINT EVOLUTION 5W-40 Synthetic mul-
tigrade oil for 4-stroke engines
SAE 5W-40, API SL, ACEA A3
Livello liquido freni
Brake fluid
Check the level:
- The fluid level is correct when it reaches "MAX"
mark.
- Fill the reserve tank up to the "MAX" mark with
brake fluid.
Brake pedal adjustment
Service and parking brake operation_
Operation check:
- The vehicle must brake in straight line.
- Park the vehicle on a slant and operate the park-
ing brake. The vehicle must remain in the same
position.
- Lift the parking brake lever from 6 to 10 notches
when a 20 kg force is applied to the lever.
PD - 810
Road test
Test drive
Engine operation at idle speed and throttle grip
partial opening
At idle speed
Note the idle speed with the engine fully heated.
At throttle grip partial opening
Performance must be regular and without pauses.
Keep speed constant at 40 - 50 km/h.
Engine operation with loaded vehicle and at a
cruising speed
Operation check:
With loaded vehicle
Accelerate up to 3/4 of throttle.
The vehicle must accelerate smoothly without any
signs of fatigue or hesitation.
At cruising speed
The vehicle must operate smoothly without any
hesitation or oscillation.
Vibration and noises
Check for possible vibration or noises.
The vehicle must operate without any vibration or
abnormal noise of the chassis as well as the body-
work.
Steering wheel
Steering wheel
Check that the steering wheel is in an upright po-
sition (spokes parallel to the cabin floor).
When the vehicle is travelling in a straight line on
a level surface, the steering wheel spokes must be
parallel to the cabin floor.
PD - 811
Steering - Wheel hub joint - Dust guard
Check that there is no interference between tyres
and other members; by turning the steering wheel
fully to the right and to the left and the dust guard;
in addition to the uniform rotation of the joint and
steering members.
1. Suspension arm strut
2. Suspension arm
3. Steering arm
PD - 812
INDEX OF TOPICS
TIME-SHEET TS
This section has the operation number for various repair procedures.
USED ABBREVIATIONS
RS right side
LS Left side
Camshaft
CAMSHAFT AND TIMING BELT
Code Action Duration
1 140011 CAMSHAFT REPLACEMENT
2 140021 CAMSHAFT TIMING SYSTEM PUL-
LEY REPLACEMENT
3 140031 CRANKSHAFT TIMING SYSTEM
BELT PULLEY REPLACEMENT
4 140041 TIMING BELT REPLACEMENT
5 140051 BELT TENSIONER REPLACE-
MENT
6 140201 UPPER AND/OR LOWER TIMING
BELT COVER - REPLACEMENT
PORTER 1.3 16V Time-sheet
TS - 815
Crankshaft
CRANKSHAFT
1 131011 CRANKSHAFT AND/OR BUSHING
REPLACEMENT
2 131051 FLYWHEEL REPLACEMENT
3 131101 CRANKSHAFT PULLEY REPLACE-
MENT
Drive shaft
Time-sheet PORTER 1.3 16V
TS - 816
PROPELLER SHAFT
1 370011 PROPELLER SHAFT - REPLACE-
MENT
Alternator
TS - 817
ALTERNATOR
1 271011 ALTERNATOR - REPLACEMENT
2 270112 ALTERNATOR - SERVICE
3 271151 ALTERNATOR PULLEY
TS - 818
Suspension leaf spring
LEAF SPRING AND SHOCK ABSORBERS
1 481011 LEAF SPRING (ONE SIDE) - RE-
PLACEMENT
2 481012 LEAF SPRING (ONE SIDE) - SERV-
ICE
3 481021 LEAF SPRING (BOTH SIDES) - RE-
PLACEMENT
4 481022 LEAF SPRING (BOTH SIDES) -
SERVICE
5 481201 LEAF SPRING SUPPORTS AND/
OR BUSHING (ONE SIDE) - RE-
PLACEMENT
6 481301 SHOCK ABSORBER (ONE SIDE) -
REPLACEMENT
7 481302 SHOCK ABSORBER (BOTH
SIDES) - REPLACEMENT
TS - 819
Battery
BATTERY
1 190011 BATTERY - REPLACEMENT
2 190101 BATTERY CABLE (TO STARTER
MOTOR) - REPLACEMENT
3 190151 BATTERY CABLE (TO GROUND) -
REPLACEMENT
TS - 820
H.T. Coil
HV COIL AND SPARK PLUGS
1 191011 HV COIL AND/OR EXTENSIONS -
REPLACEMENT
2 191101 SPARK PLUGS - REPLACEMENT
3 191201 SPARK PLUG HV CABLES (WITH
RESISTANCE) - REPLACEMENT
TS - 821
Cable harnesses
CABLE HARNESSES
1 820011 CAB INTERNAL CABLE HARNESS
- REPLACEMENT
2 820021 ENGINE CABLE HARNESS - RE-
PLACEMENT
3 820031 ENGINE CABLE HARNESS No. 2 -
REPLACEMENT
4 820101 CHASSIS CABLE HARNESS RE-
PLACEMENT
5 820151 TAIL DOOR CABLE HARNESS -
REPLACEMENT
6 820301 ROOF CABLE HARNESS - RE-
PLACEMENT
TS - 822
Gear-box
TS - 823
GEARBOX
1 331011 COMPLETE GEAR REPLACE-
MENT
2 331011 COMPLETE GEAR REPLACE-
MENT
3 331012 COMPLETE GEAR SERVICE
4 331031 OUTPUT SHAFT REPLACEMENT
5 331041 MAIN SHAFT - REPLACEMENT
6 331101 SYNCHRONISER RING REPLACE-
MENT
7 331121 5TH SPEED GEAR
8 331141 TRANSMISSION SHAFT BEARING
AND/OR TRANSMISSION SHAFT
REPLACEMENT
9 331151 REVERSER GEAR REPLACE-
MENT
10 331161 CLUTCH BELL - REPLACEMENT
11 331201 GEAR CRANKCASE REPLACE-
MENT
12 331251 REAR COVER REPLACEMENT
13 331271 REAR COVER GASKET - RE-
PLACEMENT
14 331281 REPLACING "T" SEALING RINGS
AND/OR REAR COVER
15 331351 FORK, RODS SERVICE
16 331381 ODOMETER CONTROL GEAR RE-
PLACEMENT
17 331411 ODOM. SHAFT AND/OR ODOM.
GEAR REPLACEMENT
18 331511 ODOMETER TRANSMISSION RE-
PLACEMENT
19 331551 GEAR SUPPORT - REPLACEMENT
Front chassis
TS - 824
BODYWORK (FRONT SIDE)
1 531101 FRONT MUDFLAPS (ONE SIDE) -
REPLACEMENT
2 531201 FRONT SIDE PANEL GASKET
(ONE SIDE) - REPLACEMENT
3 531301 FRONT SIDE PANEL (ONE SIDE) -
REPLACEMENT
Rear chassis
BODYWORK (REAR SIDE)
1 612011 REAR MUDFLAP REPLACEMENT -
ONE SIDE
2 612021 REAR SIDE PANEL REPLACE-
MENT - ONE SIDE
3 612031 REAR SIDE BODYWORK RE-
PLACEMENT
4 612041 CAB REAR PROTECTION RE-
PLACEMENT
TS - 825
Wheel rim
WHEEL RIM
1 430101 WHEEL RIM (1 WHEEL) - RE-
PLACEMENT
2 430111 WHEEL RIM (2 WHEEL) - RE-
PLACEMENT
3 430121 WHEEL RIM - ADDITIONAL TIME:
WHEEL ADJ USTMENT - 12 MI-
NUTES/WHEEL (THREE WHEELS)
- REPLACEMENT
4 430131 WHEEL RIM - ADDITIONAL TIME:
WHEEL ADJ USTMENT - 12 MI-
NUTES/WHEEL (FOUR WHEELS) -
REPLACEMENT
5 430201 WHEEL CAP
TS - 826
Brake cylinder
BRAKE CYLINDER
1 471051 REAR BRAKE CYLINDER- ONE
SIDE - REPLACEMENT
2 471551 REAR SHOE DISC - ONE SIDE -
REPLACEMENT
Horn
TS - 827
HORN
1 862051 HORN REPLACEMENT
Clutch assembly
CLUTCH UNIT
1 311011 CLUTCH ASSEMBLY AND/OR
CLUTCH DISC REPLACEMENT
2 311251 PRESSURE PLATE BEARING RE-
PLACEMENT
3 311611 CLUTCH LEVER AND/OR FORK
REPLACEMENT
TS - 828
Engine assembly
ENGINE UNIT
1 120011 ENGINE ASSEMBLY - REPLACE-
MENT
2 120012 COMPLETE ENGINE - SERVICE
3 120051 ENGINE, PARTIAL (BLOCK WITH
SUMP AND HEAD) - REPLACE-
MENT
4 120101 BLOCK, PARTS (BLOCK WITH PIS-
TONS AND SHAFT) - REPLACE-
MENT
TS - 829
Ducts
DUCTS
1 170011 INTAKE DUCT AND/OR GASKET
REPLACEMENT
2 170021 EXHAUST DUCT AND/OR GASKET
REPLACEMENT
3 170101 EXHAUST PIPE GASKET RE-
PLACEMENT
4 170211 MUFFLER, DUCT No. 1 - RE-
PLACEMENT
5 170171 MUFFLER REPLACEMENT, DUCT
N2
TS - 830
Oil sump
OIL SUMP
1 112011 OIL SUMP, OIL AND/OR GASKET
REPLACEMENT
TS - 831
Rear differential
TS - 832
REAR DIFFERENTIAL
1 410011 DIFFERENTIAL HOUSING AND
REAR AXLE - REPLACEMENT
2 410061 BLEEDING (OF THE REAR AXLE) -
REPLACEMENT
3 410101 DIFFERENTIAL HOUSING - RE-
PLACEMENT
4 410102 DIFFERENTIAL HOUSING - SERV-
ICE
5 410151 PINION AND CROWN REPLACE-
MENT
6 410221 DIFFERENTIAL PINION BEARINGS
- REPLACEMENT
7 410231 SEALING RING (T TYPE) - RE-
PLACEMENT
8 410251 FLANGE AND/OR OIL SEAL AND/
OR COLLAPSIBLE SPACERS - RE-
PLACEMENT
9 410311 PLANETARY GEARS AND CROWN
WHEELS REPLACEMENT
TS - 833
Brake discs
TS - 834
TS - 835
BRAKE DISC
1 473011 FRONT BRAKE DISC REPLACE-
MENT (ONE SIDE)
2 473021 FRONT BRAKE DISC REPLACE-
MENT (TWO SIDES)
3 473101 DISC BRAKE CALLIPER ASSEM-
BLY (ONE SIDE) - REPLACEMENT
4 473111 DISC BRAKE CALLIPER ASSEM-
BLY (BOTH SIDES) - REPLACE-
MENT
5 473301 DISC BRAKE SERVICE KIT (ONE
SIDE) - REPLACEMENT
6 473311 DISC BRAKE SERVICE KIT (BOTH
SIDES) - REPLACEMENT
TS - 836
Sidelight
POSITION LIGHT
1 811011 TAILLIGHT ASSEMBLY (ONE
SIDE) - REPLACEMENT
2 811031 TAILLIGHT BULB AND/OR GLASS -
ONE SIDE - REPLACEMENT
TS - 837
3 811201 LICENSE PLATE HOLDER LIGHT
REPLACEMENT
4 811211 LICENSE PLATE LIGHT GLASS
REPLACEMENT
5 811401 REVERSE LIGHT AND/OR BULB
REPLACEMENT
6 811501 REAR FOG LIGHT REPLACEMENT
Lights
HEADLAMPS
1 810011 FRONT HEADLAMP REPLACE-
MENT
2 810201 FRONT TURN INDICATOR AS-
SEMBLY - ONE SIDE - REPLACE-
MENT
3 810271 BULB REPLACEMENT: ONE SIDE
TS - 838
Air filter
AIR FILTER
1 171021 AIR FILTER ASSEMBLY - RE-
PLACEMENT
2 171051 FILTERING ELEMENT REPLACE-
MENT
3 171101 AIR FILTER FITTING REPLACE-
MENT
TS - 839
Fuel filter
FUEL FILTER
1 236021 Fuel filter - replacement
Oil filter
OIL FILTER
1 151011 OIL FILTER AND/OR GASKET - RE-
PLACEMENT
TS - 840
Parking brake
PARKING BRAKE
1 465021 PARKING BRAKE CONTROL LEV-
ER - REPLACEMENT
2 465721 PARKING BRAKE FRONT CABLE
REPLACEMENT
3 465731 PARKING BRAKE REAR CABLE
REPLACEMENT
TS - 841
Drum shoes
BRAKE SHOES AND DRUM
1 472031 REAR BRAKE SHOE REPLACE-
MENT (ONE WHEEL)
2 472041 REAR BRAKE SHOE REPLACE-
MENT (TWO WHEELS)
3 472131 REAR BRAKE DRUM REPLACE-
MENT - ONE WHEEL
4 472141 REAR BRAKE DRUM REPLACE-
MENT - TWO WHEELS
5 472231 REAR SHOE RETURN SPRING (1
WHEEL) - REPLACEMENT
6 472241 REAR SHOE RETURN SPRING -
TWO WHEELS - REPLACEMENT
Front grid
TS - 842
FRONT GRILLE
1 751011 FRONT COWL REPLACEMENT
2 751031 HEADLAMP HOUSING - ONE SIDE
- REPLACEMENT
Instrument panel
INSTRUMENT PANEL
1 830011 INSTRUMENT PANEL - REPLACE-
MENT
2 830101 GAUGES - REPLACEMENT
3 830121 ODOMETER - REPLACEMENT
4 830141 PRINTED CIRCUIT - REPLACE-
MENT
TS - 843
Fuel injection
FUEL INJECTION
1 223011 THROTTLE BODY OR GASKET -
REPLACEMENT
2 223101 FUEL INJ ECTOR - REPLACEMENT
3 223201 INJ ECTOR SUPPLY MANIFOLD -
REPLACEMENT
4 223301 FUEL PRESSURE REGULATOR -
REPLACEMENT
TS - 844
Interiors
INSIDE PARTS
1 743011 CAB ROOF INTERNAL PROTEC-
TION - REPLACEMENT
2 743021 CAB ROOF INTERNAL PROTEC-
TION - REPLACEMENT
3 743511 FRONT FLOOR CARPET - RE-
PLACEMENT
4 743651 CONSOLE REPLACEMENT
5 743751 REAR FLOOR CARPET - RE-
PLACEMENT
TS - 845
Adjusting devices
SWITCHES AND REGULATORS
1 832011 FUEL GAUGE INDICATOR RE-
PLACEMENT
2 832031 MINIMUM OIL PRESSURE INDICA-
TOR - REPLACEMENT
3 832101 STOP SWITCH - REPLACEMENT
4 832111 REVERSE GEAR BULB SWITCH -
REPLACEMENT
TS - 846
5 832251 ENGINE CHECKING COMPUTER -
REPLACEMENT
6 832301 LIGHT SWITCH REPLACEMENT
7 832431 WINDSCREEN WIPER RELAY -
REPLACEMENT
8 832311 TURN INDICATOR BLINKER RE-
PLACEMENT
9 832341 VOLTAGE REGULATOR RE-
PLACEMENT
10 832351 COURTESY LIGHT SWITCH RE-
PLACEMENT
11 832361 REAR GLASS DEFROSTER
SWITCH - REPLACEMENT
12 832371 REAR WINDSHIELD WIPER
SWITCH - REPLACEMENT
13 832381 REAR FOG LIGHT SWITCH RE-
PLACEMENT
14 832391 KEY SWITCH REPLACEMENT
15 832411 LIGHTER REPLACEMENT
16 832421 HAND BRAKE SWITCH REPLACE-
MENT
17 832441 FAN CONTROL SWITCH RE-
PLACEMENT
18 832461 FUEL PUMP RELAY - REPLACE-
MENT
19 832471 MAIN RELAY - REPLACEMENT
20 832481 PRESSURE SENSOR - REPLACE-
MENT
21 832491 FUSE BLOCK REPLACEMENT
22 832501 LAMBDA PROBE - REPLACEMENT
23 832511 VACUUM RELIEF VALVE SWITCH
- REPLACEMENT
24 832541 WATER TEMPERATURE SENSOR
- REPLACEMENT
25 832561 WATER TEMPERATURE SENSOR
- REPLACEMENT
Window sprayer
TS - 847
WINDSCREEN WASHERS
1 851051 GLASS WASHING PUMP AND MO-
TOR REPLACEMENT
2 851061 SPRINKLER - REPLAC.
3 851081 REPLACEMENT OF THE PIPE
CONNECTING THE PUMP TO THE
OPENING
4 851091 RESERVOIR AND WASHING
PUMP REPLACEMENT
Gear stick
TS - 848
GEARSHIFT LEVER
1 332301 GEAR CONTROL TRANSMISSION
REPLACEMENT
2 332401 GEAR SHIFT LEVER REPLACE-
MENT
3 332501 GEAR SHIFT LEVER KNOB RE-
PLACEMENT
TS - 849
Single-block
BLOCK
1 111011 BLOCK/CYLINDER REPLACE-
MENT
2 111151 SEALING RING REPLACEMENT
(FRONT SIDE CRANKSHAFT)
3 111201 Sealing and/or retaining ring, engine
rear side ring - Replacement
4 111251 ELASTIC SUPPORT REPLACE-
MENT
TS - 850
Starter motor
TS - 851
STARTER MOTOR
1 280011 STARTER MOTOR - REPLACE-
MENT
2 280112 MOTOR - SERVICE
3 280211 REMOTE CONTROL - REPLACE-
MENT
Rear floor panel
REAR FLOORING PANEL
1 613011 ENGINE SERVICE COMPART-
MENT COVER REPLACEMENT
2 613051 BATTERY HOUSING COVER - RE-
PLACEMENT
TS - 852
Door panel
DOOR PANEL
1 670051 FRONT DOOR PANEL (ONE SIDE)
- REPLACEMENT
2 670061 SIDE DOOR PANEL (ONE SIDE) -
REPLACEMENT
3 670201 FRONT DOOR UPPER/LOWER
HINGE (ONE SIDE) - REPLACE-
MENT
4 670301 FRONT DOOR LINING - ONE SIDE
- REPLACEMENT
5 670311 SIDE DOOR UPHOLSTERY (ONE
SIDE) - REPLACEMENT
6 670501 GUIDE FOR FRONT DOOR WIN-
DOW (ONE SIDE)- REPLACEMENT
7 670511 GUIDE FOR FRONT DOOR WIN-
DOW (ONE SIDE)- REPLACEMENT
8 670601 FRONT DOOR END OF STROKE:
ONE SIDE
9 670701 SIDE SLIDING DOOR ARM - RE-
PLACEMENT
TS - 853
10 670801 SIDE DOOR GUIDE - REPLACE-
MENT
Dashboard
TS - 854
INSTRUMENT PANEL
1 550011 INSTRUMENT PANEL REPLACE-
MENT
2 550101 INSTRUMENT PANEL FINISHING -
REPLACEMENT
3 550131 INSTRUMENT PANEL CENTRAL
FINISHING - REPLACEMENT
4 550201 GLOVEBOX REPLACEMENT
5 550211 GLOVEBOX OPEN/CLOSE LEVER
REPLACEMENT
6 550301 ASHTRAY REPLACEMENT
7 550311 VENTILATED AIR PASSAGE RE-
PLACEMENT - ONE SIDE
TS - 855
Bumper
BUMPERS
1 520011 FRONT BUMPER REPLACEMENT
2 520021 REAR BUMPER REPLACEMENT
TS - 856
Brake pedal
BRAKE PEDAL
1 467011 BRAKE PEDAL REPLACEMENT
2 467101 PEDAL PROTECTION - REPLACE-
MENT
TS - 857
Clutch pedal
CLUTCH PEDAL
1 313101 PEDAL PROTECTION - REPLACE-
MENT
2 313201 CLUTCH TRANSMISSION RE-
PLACEMENT
TS - 858
Steering column
TS - 859
COLUMN / STEERING / STEERING HOUSING / JOINTS
1 442101 ARM REPLACEMENT - ONE SIDE
2 442111 ARM REPLACEMENT - TWO
SIDES
3 442201 REPLACEMENT OF THE ARTICU-
LATED ARM WITH BAR:ONE SIDE
4 442301 UNIVERSAL J OINT REPLACE-
MENT
5 442401 STEERING HOUSING REPLACE-
MENT
6 442501 STEERING COLUMN REPLACE-
MENT
7 442601 LEFT SIDE COVER - REPLACE-
MENT
8 442611 RIGHT SIDE COVER - REPLACE-
MENT
9 442801 COLUMN PROTECTIONS - RE-
PLACEMENT
10 442851 ELASTIC J OINT - REPLACEMENT
11 442861 J OINT - REPLACEMENT
12 442871 CENTRAL ARM - REPLACEMENT
Piston/connecting rod
PISTON AND CONNECTING ROD
1 132011 PISTONS WITH PIN REPLACE-
MENT
2 132021 PISTON RINGS REPLACEMENT
3 132051 CONNECTING ROD REPLACE-
MENT
4 132061 CONNECTING ROD BUSHING RE-
PLACEMENT
TS - 860
Water pump
WATER PUMP AND THERMOSTAT
1 161011 WATER PUMP AND/OR GASKET
REPLACEMENT
2 161051 WATER PUMP PULLEY - RE-
PLACEMENT
3 161101 THERMOST. AND/OR GASKET,
WATER. OUTL. FITT. REPLACE-
MENT
TS - 861
Fuel pump
FUEL PUMP
1 234011 FUEL PUMP AND/ OR GASKET -
REPLACEMENT
2 234012 FUEL PUMP AND/ OR GASKET -
SERVICE
TS - 862
Brake fluid pump
BRAKE PUMP
1 461021 TANK AND/OR TANK PIPE RE-
PLACEMENT
2 463011 POWER BRAKE PUMP ASSEMBLY
REPLACEMENT
TS - 863
Oil pump
OIL PUMP
1 150011 OIL PUMP AND/OR O-RING RE-
PLACEMENT
2 150012 OIL PUMP AND/OR O-RING SERV-
ICE
3 150051 OIL INTAKE ASSEMBLY OR GAS-
KET - REPLACEMENT
4 150251 OIL PRESSURE SAFETY VALVE
REPLACEMENT
TS - 864
Rear van door
TAIL DOOR ( VAN )
1 642151 TAIL DOOR GLASS AND/OR GAS-
KET - REPLACEMENT
2 642321 TAIL DOOR HINGE - TWO SIDES -
REPLACEMENT
3 642361 TAIL DOOR LOCK ASSEMBLY -
REPLACEMENT
4 642391 CYLINDER KIT / REAR DOOR
LOCK KEY - REPLACEMENT
5 642711 TAIL DOOR PANEL - REPLACE-
MENT
6 642771 TAIL DOOR GASKET - REPLACE-
MENT
7 642801 TAIL DOOR UPHOLSTERY - RE-
PLACEMENT
8 642841 TAIL DOOR SHOCK ABSORBER -
REPLACEMENT
TS - 865
Rear-view mirror sun shade
SUN VISOR AND REAR-VIEW MIRROR
1 752011 EXTERNAL REAR-VIEW MIRROR -
2 752021 INTERNAL REAR-VIEW MIRROR
WITH CEILING LIGHT REPLACE-
MENT.
3 752101 SUN VISOR REPLACEMENT
4 752151 SUPPORT HANDLE REPLACE-
MENT - ONE SIDE
TS - 866
Radiator
RADIATOR AND WATER PIPES
1 160011 RADIATOR REPLACEMENT
2 160021 TANK, EXPANSION TANK, RADIA-
TOR REPLACEMENT
3 160031 PRESSURISED CAP ON RADIA-
TOR REPLACEMENT
4 160101 RADIATOR INLET PIPE REPLACE-
MENT
5 160111 RADIATOR OUTLET PIPE RE-
PLACEMENT
6 160151 ENGINE OUTLET RADIATOR
SLEEVE - REPLACEMENT
7 160201 MOTOR, FAN WITH FRAME - RE-
PLACEMENT
8 160251 V-BELT REPLACEMENT
9 160801 ENGINE SIDE PRESSURISED CAP
- REPLACEMENT
TS - 867
Radio
RADIO
1 860021 RADIO AND PARTS RELATED TO
FITTING - REPLACEMENT
2 860031 RADIO - REPLACEMENT
3 860051 LOUDSPEAKER - REPLACEMENT
4 860101 AERIAL WITH RELEVANT SUP-
PORT - REPLACEMENT
TS - 868
Heating
HEATING
1 870031 HEATING REPLACEMENT
2 870271 DEFROSTER PIPE REPLACE-
MENT - TWO SIDES
3 870311 DEFROSTER NOZZLE REPLACE-
MENT - TWO SIDES
4 870401 REPLACEMENT OF THE HEATING
CONTROL AND THE TRANSMIS-
SION
5 870771 RADIATOR ASSEMBLY REPLACE-
MENT
6 870781 FAN REPLACEMENT, HEATING
MOTOR
7 870801 RESISTOR REPLACEMENT
8 870821 HEATING WATER INLET PIPE RE-
PLACEMENT
9 870841 HEATING WATER OUTLET PIPE
REPLACEMENT
TS - 869
Front seat
FRONT SEAT
1 711011 FRONT SEAT CUSHION RE-
2 711021 SEAT BACK FOR FRONT SEAT
REPLACEMENT - ONE SIDE
3 711061 FRONT SEAT HEADREST RE-
4 711101 FRONT SEAT INTERNAL TRACK -
TS - 870
5 711151 SEAT BACK CLOSING FOR
FRONT SEAT - ONE SIDE - RE-
PLACEMENT
6 711201 FRONT SEAT CUSHION COVER
7 711251 SEAT BACK COVER FOR FRONT
SEAT (ONE SIDE) - REPLACE-
MENT
8 711301 FRONT SAFETY BELT HOOK-ONE
SIDE REPLACEMENT
9 711351 FRONT SAFETY BELT - ONE SIDE
REPLACEMENT
Rear van seat
REAR SEAT ( VAN )
1 710051 REAR SEAT CUSHION AND/OR
SEAT BACK - REPLACEMENT
2 710101 REAR SEAT CUSHION COVER -
REPLACEMENT
3 710151 SEAT BACK COVER FOR REAR
SEAT - REPLACEMENT
TS - 871
Rear half-shaft
REAR AXLE SHAFT
1 421051 REAR AXLE SHAFT (ONE SIDE) -
REPLACEMENT
2 421101 REAR AXLE SHAFT RADIAL BEAR-
ING (ONE SIDE) - REPLACEMENT
3 421201 REAR AXLE SHAFT RADIAL BEAR-
ING (BOTH SIDES) - REPLACE-
MENT
4 421301 SEALING RING (T TYPE) - RE-
PLACEMENT
TS - 872
Cam sensor
CAM SENSORS
1 192501 CAM SENSOR ASSEMBLY - RE-
PLACEMENT
2 192531 CAM SENSOR SUPPORT- RE-
PLACEMENT
3 192561 SIGNAL GENERATOR - REPLACE-
MENT
TS - 873
Fuel tank
FUEL TANK AND PIPES ( VAN )
1 237011 FUEL TANK - REPLACEMENT
2 237051 FUEL TANK CAP REPLACEMENT
3 237701 REACTION VALVE - REPLACE-
MENT
4 237811 ACTIVATED CARBON FILTER -
REPLACEMENT
TS - 874
FUEL TANK AND PIPES (PICK-UP)
1 237011 FUEL TANK - REPLACEMENT
2 237051 FUEL TANK CAP REPLACEMENT
3 237701 REACTION VALVE - REPLACE-
MENT
4 237811 ACTIVATED CARBON FILTER -
REPLACEMENT
TS - 875
Front suspensions
FRONT SUSPENSIONS AND FRONT AXLE
1 431011 LOWER SUSPENSION ARM - ONE
SIDE - REPLACEMENT
2 431051 LOWER SUSPENSION ARM -
BOTH SIDES - REPLACEMENT
3 431101 FRONT SHOCK ABSORBER
SPRING REPLACEMENT - ONE
SIDE
4 431111 FRONT SHOCK ABSORBER
SPRING REPLACEMENT - BOTH
SIDES
5 431151 FRONT SHOCK ABSORBER RE-
6 431161 FRONT SHOCK ABSORBER RE-
PLACEMENT - BOTH SIDES
7 431211 BAR SUPPORT REPLACEMENT -
ONE SIDE
8 431251 BAR BUFFER REPLACEMENT -
ONE SIDE
9 431321 FRONT WHEEL HUB REPLACE-
MENT: ONE SIDE
10 431371 SEALING RING (T TYPE) AND/
OR BEARING (ONE SIDE) - RE-
PLACEMENT
11 431381 SEALING RING (T TYPE) AND/
OR BEARING (BOTH SIDES) - RE-
PLACEMENT
TS - 876
Rear end-gate
TAILBOARD
1 611011 TAILBOARD REPLACEMENT
2 611101 TAILBOARD HOOK REPLACE-
MENT
TS - 877
Spare wheel mounting bracket
SPARE WHEEL SUPPORT
1 511201 SPARE WHEEL SUPPORT - RE-
PLACEMENT
TS - 878
Plates
LABELS
1 750011 PLATE REPLACEMENT - SINGLE
PIECE
TS - 879
Wiper
WINDSCREEN WIPER
1 850051 REPLACEMENT OF THE FRONT
WINDSCREEN WIPER ARM AND/
OR BLADE
2 850161 FRONT WINDSCREEN WIPER MO-
TOR REPLACEMENT
3 850171 FRONT WINDSCREEN WIPER AR-
TICULATION REPLACEMENT
TS - 880
Rear van wiper
REAR WINDSCREEN WIPER AND REAR WINDOW WASHER ( VAN )
1 852011 WINDSCREEN WIPER ARM AND/
OR BLADE - REPLACEMENT
2 852051 MOTOR AND REAR WINDSCREEN
WIPER SUPPORT - REPLACE-
MENT
3 852101 REAR WINDOW WASHER SPRAY-
ER - REPLACEMENT
TS - 881
Head
HEAD
1 110011 HEAD/CYLINDER - REPLAC.
2 110051 GASKET/HEAD REPLACEMENT
3 110101 REPLACEMENT OF COVER OR
HEAD AND/OR HEAD GASKET/
COVER
4 110201 OIL SEAL RING (CAMSHAFT) RE-
PLACEMENT
5 110131 OIL FILLER CAP - REPLACEMENT
TS - 882
Throttle cable
ACCELERATOR TRANSMISSION
1 552031 ACCELERATOR TRANSMISSION
REPLACEMENT
TS - 883
Brake hoses
BRAKE PIPES AND CALIBRATOR
1 464011 FRONT HOSE REPLACEMENT
2 464051 REAR BRAKE HOSE REPLACE-
MENT
3 464751 POWER BRAKE REGULATOR AS-
SEMBLY REPLACEMENT
TS - 884
Valves
VALVES
1 141011 VALVE, VALVE GUIDE REPLACE-
MENT
2 141031 SPRING, CAP PLATE AND/OR
COTTERS AND/OR SEAL. RING
REPLAC.
3 141101 PIN, ROCKING LEVER REPLACE-
MENT
TS - 885
Windows
WINDOWS
1 554011 WINDSHIELD AND GASKET RE-
PLACEMENT
2 554051 REAR GLASS AND/OR GASKET
REPLACEMENT
Van side window
TS - 886
SIDE GLASS ( VAN )
1 645011 SIDE GLASS STRIP (ONE SIDE) -
REPLACEMENT
2 645021 SIDE GLASS AND/OR PROFILE -
REPLACEMENT
Frameless side window
DOOR GLASS AND PROFILE
1 671011 FRONT DOOR GLASS REPLACE-
MENT - ONE SIDE
2 671021 SIDE DOOR GLASS (ONE SIDE) -
REPLACEMENT
3 671051 FRONT DOOR GLASS GUIDE RE-
4 671061 FRONT DOOR GLASS GUIDE
TS - 887
5 671251 FRONT DOOR INTERNAL PLATE
REPLACEMENT: ONE SIDE
6 561261 SIDE DOOR INTERNAL PLATE
7 671271 FRONT DOOR EXTERNAL GLASS
EDGE: ONE SIDE
8 671281 SIDE DOOR EXTERNAL GLASS
EDGE (ONE SIDE) - REPLACE-
MENT
9 671351 FRONT DOOR GASKET REPLACE-
MENT: ONE SIDE
10 671361 SIDE DOOR GASKET (ONE SIDE) -
REPLACEMENT
TS - 888
Steering
STEERING WHEEL
1 441071 HORN CONTACT RING REPLACE-
MENT
TS - 889
2 441101 STEERING WHEEL REPLACE-
MENT
3 441121 HORN CONTACT SQUARE PLATE
REPLACEMENT
4 441151 HORN BUTTON REPLACEMENT
TS - 890
B
Battery: 820
Belt: 232, 236, 240, 244, 247
Bodywork:
Brakes: 68, 69
Bulbs: 150, 152, 154
C
Chassis: 70, 740, 804, 824, 825
Checks: 357
Cleaning: 808
Clearance:
Control: 561, 664, 670, 682
Coolant: 48, 67, 360, 370, 808
D
Differential: 47, 595, 596, 832
Doors: 745
E
Engine: 44, 45, 66, 70, 225, 806, 809, 810, 829
F
Filter: 44, 126, 361, 839, 840
Fluid: 615, 863
Fuel: 67, 361, 840, 844, 862, 874
Fuses: 83
G
Gearshift:
H
Headlamps:
Horn: 802, 827
I
Identification: 22
Instrument panel: 779, 843
L
Level: 66
Lights: 157, 803, 804, 838
M
Maintenance: 13, 43
O
Oil: 4547, 66, 67, 248, 298, 349, 358, 810, 831, 840, 864
P
Pressure: 66, 260, 800
Products: 44
R
Remote control:
S
Safety: 10
Seats: 275, 277
Shock Absorbers:
Spark plugs:
Specifications:
Switch: 88
System: 54, 72, 348, 360, 361, 378, 611, 621
T
Tank: 874
V
Van: 865, 871, 881, 886
Vehicle: 29, 655
W
Warning: 157, 804
Wheel: 685, 687, 710, 799, 811, 826, 878
Windows: 742, 886

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